Experiment - 01

TENSION TEST

AIM: To determine ultimate tensile stress of a metal.

OBJECTIVE: To conduct a tensile test on a mild steel specimen and determine the
following:
1. Limit of proportionality
2. Elastic limit
3. Yield strength
4. Ultimate strength
5. Young‟s modulus of elasticity
6. Percentage elongation
7. Percentage reduction in area.

APPARATUS:
1. Universal Testing Machine (UTM)
2. Mild steel specimens
3. Graph paper
4. Scale
5. Vernier Caliper

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DIAGRAM

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M/C SPECIFICATIONS:

Capacity: 400 KN.

Model: UTK-40.

SR.No: 2013/1073.

Mfd. By: Krystal Equipments, Ichalkaranji, M.H, India.

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 form 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.

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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.

DESCRIPTION OF UTM AND EXTENSOMETER:

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 pecimen 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 tan Electric motor driven the pump is mounted on four studs

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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 tests.

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

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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.

Stress-strain graph of Mild Steel

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

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 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.
OBESERVATIONS:

A) Original dimensions Gauge Length = ------------

Diameter = ---------

Area = --------------

B) Final Dimensions:

Gauge Length = -------------------

Diameter = -----------------

Area = ----------------------

TABULATION:- (Cross check ‘E’ with reference table 1.0)

SL No Extension (mm) Load (N) Average load Young‟s Modulus

Left Right Left Right
1
2
3
4
5
6

2
Elastic limit = N/mm

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Young‟s Modulus =

% of elongation =

% of reduction in area =

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 Experiment No - 04

TORSION TEST

OBJECTIVE:
To conduct torsion test on mild steel or cast iron specimen to determine modulus of rigidity.

APPARATUS:

1. A torsion test machine along with angle of twist measuring attachment.

2. Standard specimen of mild steel or cast iron.
3. Steel rule.
4. Vernier caliper or a micrometer.

Torsion testing machine:

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M/C SPECIFICATIONS:

Capacity: Torque Range: 0-10 Kg-m.

Model: TTM-10..

SR.No: 2001/1012.

Mfd. By: Macro Testing Machines, Ichalkaranji, M.H, India.

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THEORY:

For transmitting power through a rotating shaft it is necessary to apply a turning force. The
force is applied tangentially and in the plane of transverse cross section. The torque or
twisting moment may be calculated by multiplying two opposite turning moments. It is said
to be in pure torsion and it will exhibit the tendency of shearing off at every cross section
which is perpendicular to the longitudinal axis.

Torsion equation:

Torsion equation is given by below

T/J = τ/R= Gθ/L

G = T L/J θ N/mm2

T= maximum twisting torque (N mm)

J = polar moment of inertia (mm4) = π d4/32 τ = shear stress (N/mm2)

G = modulus of rigidity (N/mm2) θ = angle of twist in radians

L= length of shaft under torsion (mm)

Assumptions made for getting torsion equation

1. The material of the shaft is uniform throughout.

2. The shaft, circular in section remain circular after loading.
3. Plane sections of shaft normal to its axis before loading remain plane after the torque
have been applied.
4. The twist along the length of the shaft is uniform throughout.
5. The distance between any two normal-sections remains the same after the application of
torque.
6. Maximum shear stress induced in the shaft due to application of torque does not exceed
its elastic limit.

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PROCEDURE:-

1. Select the driving dogs to suit the size of the specimen and clamp it in the machine by
adjusting the length of the specimen by means of a sliding spindle.
2. Measure the diameter at about three places and take the average value.
3. Choose the appropriate range by capacity change lever
4. Set the maximum load pointer to zero.
5. Set the protractor to zero for convenience and clamp it by means of knurled screw.
6. Carry out straining by rotating the hand wheel in either direction.
7. Load the machine in suitable increments.
8. Then load out to failure as to cause equal increments of strain reading.
9. Plot a torque- twist (T- θ) graph.
10. Read off co-ordinates of a convenient point from the straight line portion of the torque
twist (T-θ) graph and calculate the value of G by using relation.

OBESERVATIONS:-

Gauge length of the specimen, L = ………

Diameter of the specimen, d = ………

Polar moment of inertia, J = π d4/32 = ........

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 TABULATION: (Cross check ‘G’ with reference table 1.0)

Sl. No. Torque, Torque, Angle of twist Modulus Average G,

Kg-cm N - mm Degrees Radians Rigidity, G N/mm2

N/mm2

RESULT:-

Thus the torsion test on given mild steel specimen is done and the modulus of rigidity is ------
-N/mm2.

GRAPH:
Torque Vs Angle of Twist

PRECAUTIONS:-

1) Measure the dimensions of the specimen carefully

2) Measure the Angle of twist accurately for the corresponding value of Torque.
3) The specimen should be properly to get between the jaws.
4) After breaking specimen stop to m/c.

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 BRINELL’S HARDNESS TEST

AIM:

To find the brinell‟s hardness number of the given metals using brinell‟s hardness
testing machine.

APPARATUS:

Brinell‟s hardness tester, Optical microscope.

THEORY:
Hardness of a material is generally defined as Resistance t o permanent indentation
under static or dynamic loads. However it also refers to stiffness or to resistance to
scratching, abrasion or cutting. Indentation hardness maybe measured by various
hardness tests, such as Rockwell, Vickers, Brinnells hardness etc. In Brinell‟s
hardness test, a hard steel ball, under specified conditions of load and time, is
forced into the surface of the material under test and the diameter of the impression
is measured. Hardness number is defined as the load in kilograms per square
millimeters of the surface area of indentation. This number depends on the
magnitude of the load applied, material and geometry of the indentor.
For the Brinell‟s hardness number, the diameter of the indentor and load shall be taken
from the following table:

Ball dia (D) Load kilograms

Ferrous metals Non ferrous metals

Brass 10 D2 Alluminium 5
Steel& iron 30 D2 D2
10 mm 3000 10 500
00
5 mm 750 25
0

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 Brinell’s hardness number (HB) is given by

HB = Load on ball in kg

Surface area of indentation in sq.mm

2P

πD(d-√ D2-d2)

Where: P=load in kg
D=diameter of indentor in mm
d=average diameter of impression in
mm

PROCEDURE:

 Select the proper diameter of the indentor and load.

 Start the machine by pushing the green button of starter and allow oil to
circulate for few minutes.

 Keep the hand lever in position A.

 Place the specimen securely on the testing table. Turn the hand wheel in
clockwise direction, so that the specimen will push the indentor and will show a
reading on dial gauge. The movement will continue until the long pointer will
stop at „0‟ and small pointer at red dot when the initial load of 250kg is applied.
If little error exists the same can be adjusted by rotating the outer ring dial gauge.

 Turn the handle from position „A‟ to „B‟ so that the total system is
brought into action.

 When the long pointer of dial gauge reaches a steady position, the load
may be released by taking back the lever to position „A‟.

 Turn back the hand wheel and remove the specimen.

 The diameter of the impression can be found by using optical microscope.

 Read the hardness number from the tables.

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 OBSERVATIONS:

Table: 1.1

Sl No Material Load Diameter of BHN(kg/mm^2)

impression(mm)

Model Table

Sl No. Material Load Diameter of BHN(kg/mm^2)

impression(mm)
1 EN-8 3000 5 144.6

2 EN-24 3000 4.4 142.6

3 Stainless 3000 4.8 155.2

steel(SS)
4 Aluminum(Al) 500 3 69.15

Important Viva Questions:

1. What is the relation between Brinell‟s hardness number and Rockwell‟s

hardness number

PRECAUTIONS:
1. Operate the hand lever from A to B several times to raise and
lower the weights in order to eliminate air from the hydraulic system.
2. Operate it slowly for accurate results.

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RESULT:

The Brinell‟s hardness number of EN-8

The Brinell‟s hardness number of EN-24

The Brinell‟s hardness number of Stain less Steel

The Brinell‟s hardness number of Alluminium

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BRINNELL’S HARDNESS TESTING MACHINE

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 Experiment No. – 07

COMPRESSION TEST

OBJECTIVE:-
To perform compression test on UTM.

APPARATUS:-
1. UTM or A compression testing m/c,
2. Cylindrical or cube shaped specimen,
3. Vernier caliper,
4. Liner scale.

DIAGRAM:-

THEORY:-

Bricks are used in construction of either load bearing walls or in portion walls in case of
frame structure. In bad bearing walls total weight from slab and upper floor comes directly
through brick and then it is transversed to the foundation. In case the bricks are loaded with
compressive nature of force on other hand in case of frame structure bricks are used only for
construction of portion walls, layers comes directly on the lower layers or wall. In this case
bricks are loaded with compressive nature of force. Hence for safely measures before using

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the bricks in actual practice they have to be tested in laboratory for their compressive
strength.

PROCEDURE: -

1. Select some brick with uniform shape and size.

2. Measure it‟s all dimensions. (LxBxH)
3. Now fill the frog of the brick with fine sand.
4. Place the brick on the lower platform of compression testing machine and lower the
spindle till the upper motion of ram is offered by a specimen the oil pressure start
increasing the pointer start returning to zero leaving the drug pointer that is
maximum reading which can be noted down.

TABULATION: - (Refer Tables)

S. No. L x B x H, Area, Load Compressive Avg. Compressive

Cm3 L x B, Cm2 (P), N Strength Strength (P/A),

(P/A), KPa KPa

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 CALCULATION:-

Max. Load at failure

Compressive Strength = ----------------------------- KPa

Loaded Area of brick

RESULT:-
The average compressive strength of new brick sample is found to be ………. KPa

PRECAUTIONS:-
1) Measure the dimensions of Brick accurately.
2) Specimen should be placed as for as possible in the of lower plate.
3) The range of the gauge fitted on the machine should not be more than double the
breaking load of specimen for reliable results.

Compressive and tensile strength of some common materials :

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 Experiment No – 06

b) IMPACT TEST (CHARPY)

AIM:

To determined impact strength of steel.

OBJECT: -

To determine the impact strength of steel by (Charpy test)

APPARATUS: -

1. Impact testing machine

2. A steel specimen 10 mm x 10 mm X 55mm

DIAGRAM:-

THEORY:-

An impact test signifies toughness of material that is ability of material to absorb energy
during plastic deformation. Static tension tests of unmatched specimens do not always reveal
the susceptibility of a metal to brittle fracture. This important factor is determined by impact
test. Toughness takes into account both the strength and ductility of the material. Several
engineering materials have to withstand impact or suddenly applied loads while in service.
Impact strengths are generally lower as compared to strengths achieved under slowly applied
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loads. Of all types of impact tests, the notch bar tests are most extensively used. Therefore, the
impact test measures the energy necessary to fracture a standard notch bar by applying an
impulse load. The test measures the notch toughness of material under shock loading. Values
obtained from these tests are not of much utility to design problems directly and are highly
arbitrary. Still it is important to note that it provides a good way of comparing toughness of
various materials or toughness of the same material under different condition. This test can
also be used to assess the ductile brittle transition temperature of the material occurring due to
lowering of temperature.

PROCEDURE:-

(b) Charpy Test

1. With the striking hammer (pendulum) in safe test position, firmly hold the steel specimen in
impact testing machines vice in such a way that the notch faces s the hammer and is half
inside and half above the top surface of the vice.
2. Bring the striking hammer to its top most striking position unless it is already there, and
lock it at that position.
3. Bring indicator of the machine to zero, or follow the instructions of the operating manual
supplied with the machine.
4. Release the hammer. It will fall due to gravity and break the specimen through its
momentum, the total energy is not absorbed by the specimen. Then it continues to swing.
At its topmost height after breaking the specimen, the indicator stops moving, while the
pendulum falls back. Note the indicator at that topmost final position.
5. The specimen is placed on supports or anvil so that the blow of hammer is opposite to the
notch.
OBESERVATIONS:-

Charpy test

1. Impact value of - Mild Steel ------------N-m

2. Impact value of - Brass ------------ N-m

3. Impact value of - Aluminum ------------N-m

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RESULT:-

i. The energy absorbed for Mild Steel is found out to be (K) -------------Joules.
ii. The energy absorbed for Brass is found out to be (K) ------------ Joules.

iii. The energy absorbed for Aluminum is found out to be (K) -------------Joules

iv. Impact strength of the specimen, (K/A) = -------------------J/mm2

PRECAUTIONS:-

1 Measure the dimensions of the specimen carefully.

2 Locate the specimen (Charpy test) in such a way that the hammer, strikes it at the
middle.
3 Note down readings carefully.

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