EXPERIMENT NO.

– 01
AIM: - Study and demonstration of Universal Testing Machine & its attachments.

OBJECT: - To Study the various component parts of the Universal Testing Machine
(U.T.M.) & test procedures of various practical’s to be performed.

APPARATUS: - Universal Testing Machine with all attachment i.e. shears test
attachment, bending attachment, tension grips, compression test attachment
etc.
DIAGRAM:-
THEORY : - The Universal Testing Machine consists of two units. 1) Loading unit,
2) Control panel.

LOADING UNIT:-
It consists of main hydraulic cylinder with robust base inside. The piston which moves
up and down. The chain driven by electric motor which is fitted on left hand side. The
screw column maintained in the base can be rotated using above arrangement of chain.
Each column passes through the main nut which is fitted in the lower cross head.
The lower table connected to main piston through a ball & the ball seat is joined to
ensure axial loading. There is a connection between lower table and upper head
assembly that moves up and down with main piston. The measurement of this
assembly is carried out by number of bearings which slides over the columns.
The test specimen each fixed in the job is known as ‘Jack Job’. To fix up the
specimen tightly, the movement of jack job is achieved helically by handle.

CONTROL PANEL:-
It consists of oil tank having a hydraulic oil level sight glass for checking the oil level.
The pump is displacement type piston pump having free plungers those ensure for
continuation of high pressure. The pump is fixed to the tank from bottom. The suction
& delivery valve are fitted to the pump near tank Electric motor driven the pump is
mounted on four studs which is fitted on the right side of the tank. There is an
arrangement for loosing or tightening of the valve. The four valves on control panel
control the oil stroke in the hydraulic system. The loading system works as described
below.
The return valve is close, oil delivered by the pump through the flow control
valves to the cylinder & the piston goes up. Pressure starts developing & either the
specimen breaks or the load having maximum value is controlled with the base
dynameters consisting in a cylinder in which the piston reciprocates. The switches
have upper and lower push at the control panel for the downward & upward
movement of the movable head. The on & off switch provided on the control panel &
the pilot lamp shows the transmission of main supply.

METHOD OF TESTING:-
Initial Adjustment: - before testing adjust the pendulum with respect to capacity of the
test
i.e. 8 Tones; 10 Tones; 20 Tones; 40 Tones etc.
For ex: - A specimen of 6 tones capacity gives more accurate result of 10 Tones
capacity range instead of 20 Tones capacity range. These ranges of capacity are
adjusted on the dial with the help of range selector knob. The control weights of the
pendulum are adjusted correctly. The ink should be inserted in pen holder of recording
paper around the drum & the testing process is started depending upon the types of test
as mentioned below.
TENSION TEST:-
Select the proper job and complete upper and lower check adjustment. Apply
some Greece to the tapered surface of specimen or groove. Then operate the upper cross
head grip operation handle & grip the upper end of test specimen fully in to the groove.
Keep the lower left valve in fully close position. Open the right valve & close it after
lower table is slightly lifted. Adjust the lower points to zero with the help of adjusting
knob. This is necessary to remove the dead weight of the lower table. Then lock the jobs
in this position by operating job working handle. Then open the left control valve. The
printer on dial gauge at which the specimen breaks slightly return back & corresponding
load is known as breaking load & maximum load is known as the ultimate load.

COMPRESSION TEST:-
Fix upper and lower pressure plates to the upper stationary head & lower table
respectively. Place the specimen on the lower plate in order to grip. Then adjust zero by
lifting the lower table. Then perform the test in the same manner as described in tension
test.

FLEXURAL OR BENDING TEST:-

Keep the bending table on the lower table in such a way that the central position of the
bending table is fixed in the central location value of the lower table. The bending
supports are adjusted to required distance. Stuffers at the back of the bending table at
different positions. Then place the specimen on bending table & apply the load by
bending attachment at the upper stationary head. Then perform the test in the same
manner as described in tension test.

BRINELL HARDNESS TEST:-

Place the specimen on the lower table & lift it up slightly. Adjust the zero
fixed value at the bottom side of the lower cross head. Increase the load slowly ultimate
load value is obtained. Then release the load slowly with left control valve. Get the
impression of a suitable value of five to ten millimeter on the specimen & measure the
diameter of the impression correctly by microscope & calculate Brinell hardness.

SHEAR TEST:-Place the shear test attachment on the lower table, this attachment
consists of cutter. The specimen is inserted in roles of shear test attachment & lift the
lower table so that the zero is adjusted, then apply the load such that the specimen breaks in
two or three pieces. If the specimen breaks in two pieces then it will be in angle shear, & if it
breaks in three pieces then it will be in double shear.

STUDY OF EXTENSOMETER:- This instrument is an attachment to Universal /

Tensile Testing Machines. This measures the elongation of a test place on load for the set
gauge length. The least count of measurement being 0.01 mm, and maximum elongation
measurement up to 3 mm. This elongation measurement helps in finding out the proof
stress at the required percentage elongation.
WORKING OF THE INSTRUMENT:-
The required gauge length(between 30to 120 ) is set by adjusting the upper knife edges (
3 ) A scale ( 2 ) is provided for this purpose . Hold the specimen in the upper and lower
jaws of Tensile / Universal Testing Machine. Position the extensometer on the
specimen. Position upper clamp (4) To press upper knife edges on the specimen. The
extensometer will be now fixed to the specimen by spring pressure. Set zero on both
the dial gauges by zero adjust screws (7 ). Start loading the specimen and take the
reading of load on the machine at required elongation or the elongation at required
load. Force setter accuracies mean of both the dial gauge ( 8) readings should be taken
as elongation. It is very important to note & follow the practice of removing the
extensometer from the specimen before the specimen breaks otherwise the instrument
will be totally damaged. As a safety, while testing the instrument may be kept hanging
from a fixed support by a slightly loose thread.
TECHNICAL DATA:-
Measuring Range: 0 – 3 mm.
Least Count: 0. 01 mm.
Gauge Length adjustable from: 30 – 120 mm
Specimen Size: 1 to 20mm Round or Flats up to 20 x 20 mm.

A) Stress-strain graph of Mild Steel

 B) Stress-strain graphs of different materials.

• Curve A shows a brittle material. This material is also strong because

there is little strain for a high stress. The fracture of a brittle material is
sudden and catastrophic, with little or no plastic deformation. Brittle
materials crack under tension and the stress increases around the cracks.
Cracks propagate less under compression.
• Curve B is a strong material which is not ductile. Steel wires stretch
very little, and break suddenly. There can be a lot of elastic strain
energy in a steel wire under tension and it will “whiplash” if it breaks.
The ends are razor sharp and such a failure is very dangerous indeed.
• Curve C is a ductile material
• Curve D is a plastic material. Notice a very large strain for a small
stress. The material will not go back to its original length.
 EXPERIMENT NO. –2

AIM: -To determine tensile test on a metal.

OBJECT: - To conduct a tensile test on a mild steel specimen and
determine the following:
(i) Limit of proportionality (ii) Elastic limit
(iii) Yield strength (IV) Ultimate strength
(v) Young’s modulus of elasticity (VI) Percentage elongation
(vii) Percentage reduction in area.
APPARATUS: -
(i) Universal Testing Machine (UTM)
(ii) Mild steel specimens
(iii) Graph paper
(iv) Scale
(v) Vernier Caliper
DIAGRAM:-
THEORY:-The tensile test is most applied one, of all mechanical tests. In this
test ends of test piece are fixed into grips connected to a straining device
and to a load measuring device. If the applied load is small enough, the
deformation of any solid body is entirely elastic. An elastically deformed
solid will return to its original from as soon as load is removed. However,
if the load is too large, the material can be deformed permanently. The
initial part of the tension curve which is recoverable immediately after
unloading is termed. As elastic and the rest of the curve which represents
the manner in which solid undergoes plastic deformation is termed plastic.
The stress below which the deformations essentially entirely elastic is
known as the yield strength of material. In some material the onset of
plastic deformation is denoted by a sudden drop in load indicating both an
upper and a lower yield point. However, some materials do not exhibit a
sharp yield point.
During plastic deformation, at larger extensions strain hardening cannot
compensate for the decrease in section and thus the load passes through a
maximum and then begins to decrease. This stage the “ultimate strength”’
which is defined as the ratio of the load on the specimen to original cross-
sectional area, reaches a maximum value. Further loading will eventually
cause ‘neck’ formation and rupture.
PROCEDURE:-
1) Measure the original length and diameter of the specimen. The length
may either be length of gauge section which is marked on the specimen
with a preset punch or the total length of the specimen.
2. Insert the specimen into grips of the test machine and attach strain-
measuring device to it.
3. Begin the load application and record load versus elongation data.
4. Take readings more frequently as yield point is approached.
5. Measure elongation values with the help of dividers and a ruler.
6. Continue the test till Fracture occurs.
7. By joining the two broken halves of the specimen together,
measure the final length and diameter of specimen.
OBESERVATION:- A) Material:
A) Original dimensions

Length = ------------
Diameter = ---------
Area = --------------
B) Final Dimensions:

Length = -------------------
 Diameter = -----------------
Area = -----------------------
OBESERVATION TABLE:-
S.No Load(N) Original Extension
Load Increase in length
Gauge length (mm)
Stress = Area Strain = ---------
Original length
2
(N/mm )

1
2
3
4
5
To plot the stress strain curve and determine the following.
(i) Limit pf proportion
Load at limit of proportionaliy
= =….N/m
Original area of cross-section

2
(ii) Elastic limit = load at elastic limit N/mm
Original area of c/s

(iii) Yield strength

Yield load
2
= =….N/mm
Original area of cross-section

(iv) Ultimate strength

Maximum tensile load
2
= =….N/mm
Original area of cross-section

2
(v) Young’s modulus, E -= stress below propornality limit N/mm
Corresponding strain

S
 (vi) Percentage elongation

Final length (at fracture) – original length

= =….%
Original length

(vii) Percentage reduction in area

Original area-area at fracture

= =….%
Original area

RESULT:- i) Average Breaking Stress = ii)

Ultimate Stress = iii) Average %
Elongation =

PRECAUTION:-
1. If the strain measuring device is an extensometer it should be
removed before necking begins.
2. Measure deflection on scale accurately & carefully
 EXPERIMENT NO. –3

AIM: -To study the mechanical properties of cast iron specimen under
compression.
Compression Test on Cast Iron
A compression test is a method for determining the behaviour of materials
under a compressive load. Compression tests are conducted by loading the test
specimen between two plates and then applying a force to the specimen by
moving the crossheads together. Here the test specimen is compressed and
deformation versus the applied load is recorded. The compression test is used
to determine elastic limit, proportional limit,yield point, yield strength, and
(for some materials) compressive strength, modulus of elasticity, secant
modulus, tangent modulus. Compression tests are of high importance because
it helps to calculate the different material properties that are applicable to hot
as well as cold metal forging employed for different metal forming
applications. Brittle materials in compression will have an initial linear region
followed by a region in which the shortening increases at a higher rate than
does the load. Thus the compression stress-strain diagram has a shape that is
similar to the shape of the tensile diagram.

Test Specimen:
In compression testing the material having constant cross sectional area
throughout their full length will be used. The gaugelength of a sample in a
compression test is its full length. A serious problem in compression testing is
the possibility that the sample or load chain may buckle (form bulges or bend)
prior to material failure. To prevent this specimens are kept short and stubby.
The effect of buckling and friction can be minimized by selecting the length to
diameter ratio of the specimen carefully.
 Several materials which are good in tension are poor in compression; contrary
to this many materials which are poor in tension are very strong in
compression. Cast iron is an example of such material. For main brittle
materials the elastic properties like elastic limit, modulus of elasticity, yield
strength and modulus of resilience are similar in compression and tension.
High strength steel and aluminium alloys do not exhibit a yield point, when a
yield point is not easily defined based on the shape of the stress-strain curve,
then an offset yield point (proof stress) is arbitrarily defined. The value for
this is commonly set at 0.2% plastic strain.Materials like cast iron are weak in
tension because of the presence of sub-microscopic cracks and faults. In
compression test the cross sectional area of the specimen increases which
tends to increase the compressive strength. Therefore reach much higher
ultimate stresses in compression than in tension. Also the brittle materials
actually fracture or break at the maximum load by splitting or by cracking.
The brittle test piece fractures in compression because of shearing along a
plane inclined to the axis. The orientation of the plane of shear is affected by
the compressive stresses, the shear of plane may vary from 35o and 45o along
with the axis. In brittle materials some lateral bulging will tend to happen
during loading, such lateral deformation is greatly controlled at flat specimen
ends because of friction between the specimen ends and the platens. This
friction decreases as the length of the specimen increases.

RELEVANT INDIAN STANDARD FOR COMPRESSION TEST:

1. IS 13780 (1993): Hardmetals - Compression Test.
OBJECTIVE:
To study the mechanical properties of cast iron specimen under compression.
STEPS:
1. Sample is dragged to be placed in the UTM and a dial gauge is mounted. Click on the knob of dial gauge
to adjust it to zero.
2. Start the loading process click ON the green button.
3. Note down the deflections using dial gauge for corresponding load intervals as the specimen fails the
loading is stopped by clicking on the red button. There is option to download the dial gauge reading.
4. The graph of the experiment is shown here, Click on VIEW DATA or VIEW SLOPE to view test result
or the slope drawn to the graph.
5. Observation.
 EXPERIMENT NO :- 4
AIM: -To determined Shear Test of Steel.
OBJECT: - To conduct shear test on specimens under double shear:
APPARATUS: - i) Universal testing machine.
ii) Shear test attachment.
iii) Specimens.
DIAGRAM:-

THEORY: -Place the shear test attachment on the lower table, this attachment
consists of cutter. The specimen is inserted in shear test attachment &
lift the lower table so that the zero is adjusted, then apply the load such
that the specimen breaks in two or three pieces. If the specimen breaks
in two pieces then it will be in single
shear & if it breaks in three pieces then it will be in double shear.
 PROCEDURE:
1. Insert the specimen in position and grip one end of the attachment in
the upper portion and one end in the lower portion.
2. Switch on the main switch of universal testing machine machine.
3. The drag indicator in contact with the main indicator.
4. Select the suitable range of loads and space the corresponding weight
in the pendulum and balance it if necessary with the help of small
balancing weights.
5. Operate (push) buttons for driving the motor to drive the pump.
6. Gradually move the head control level in left-hand direction till the
specimen shears.
7. Down the load at which the specimen shears.
8. Stop the machine and remove the specimen
Repeat the experiment with other
specimens. OBESERVATION:-
Diameter of the Rod, D = ….. mm
2 2
Cross-section area of the Rod (in double shear) = 2x π/4x d =.. mm

Strength Of Materials
 Load taken by the Specimen at the time of failure , W

= N Strength of rod against Shearin

2 2
ƒ = W / 2x π/4x d N/mm

RESULT:
The Shear strength of mild steel specimen is found to be
2
=..............................N/mm

PRECAUTION :-
1 The measuring range should not be changed at any stage during the test.
2. The inner diameter of the hole in the shear stress attachment should be
slightly greater than that of the specimen.
3. Measure the diameter of the specimen accurately.