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MCB 3023 ENGINEERING MATERIAL

LAB PROGRESS REPORT
GROUP 2
NAME: STUDENT ID
ESTRELLA MATUTINA
OYONO ABANG (LEADER)
15753
PATRICIO AGUILAR PINO 15755
DIONISIO MIGUEL NTUTUMU
NSANG
15765
WONG HOONG WEI 15860
ARIFF HAKIMY B.MOHD
KARIM
15868

LECTURER: Assoc Prof Dr Othman B Mamat
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Table of Contents

1. PROJECT BACKGROUND ........................................................................................................ 3
1.1 Sample Description .................................................................................................................. 3
(a) Physical appearance ............................................................................................................... 3
(b) Size and Specification of The Sample ................................................................................... 4
(c) Mechanical characteristics ..................................................................................................... 4
(d) Chemical Characteristics ....................................................................................................... 4
(e) Optical characteristics ............................................................................................................ 4
1.2 Problem statement .................................................................................................................... 4
1.3 Objectives ................................................................................................................................. 5
1.4 Scopes ...................................................................................................................................... 5
2.0 LTERATURE REVEW .............................................................................................................. 6
3.0 METHODOLOGY ....................................................................................................................... 11
3.1 Small-size ASTM E8M Round Tension Test Specimen Procedures ..................................... 11
3.2 Project Activity ...................................................................................................................... 12
3.2.1 Task Assignment .................................................................................................................. 12
3.2.2 Scheduling ............................................................................................................................ 12
3.2.3 Minute of Meeting ............................................................................................................... 13
3.3 Project Plan & Gantt Chart ........................................................................................................ 16
3.4 Equipment .............................................................................................................................. 18
4.0 REFERENCE ............................................................................................................................... 19


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1. PROJECT BACKGROUND


1.1 Sample Description
In order to accomplish the lab objectives, our group was assigned with three samples of
aluminum rods as per shown in Figure 1a. The sample shows the following characteristics:
Picture of our real sample:


Figure 1a: material sample
(a) Physical appearance

The colour of the sample is slightly dark grey. Figure 1b shows the shape and size of the
sample. It has two shoulders or grip sections and a gauge section between both shoulders.
The shoulders are large enough that they can be properly gripped. The gage section
presents a smaller cross-section so that failure and deformation can occur in this area
during testing.



Figure 1b: Sample Physical Appearance





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(b) Size and Specification of The Sample
Overall length = 10 cm
Distance between shoulders = 5 cm
Diameter/width of gage section = 0.6 cm
Diameter/width of grip section = 1 cm

(c) Mechanical characteristics
The aluminum rod presents a smooth and sensitively hard surface.

(d) Chemical Characteristics
No corrosion is present on the sample surface. Also the sample is free of oxidation.

(e) Optical characteristics
The sample is slightly shiny and it presents poor reflective characteristic. No transparent
material.

1.2 Problem statement
Nowadays material availability is what makes our life different from our ancestors. Materials
are used in a vast field of activities such as construction and engineering industry. When in
service, materials are subjected to loads, forces, vibrations, etc. Therefore, it is very important to
know the characteristics and mechanical properties of any material before being selected for a
specific use. Knowing the material properties, we are able to make the correct choice when
determining the most suitable material needed for a specific task; in that way we can save
money, lives and ensure project success. The mechanical properties of material are determined
by performing several laboratory testing that simulate the real condition under which material
will be subjected while in use. Based on the physical shape and design of the sample assigned to
our group, the most suitable test to perform to determine the material properties is the tensile
test. The type of material, size and shape of the sample allow it to fix adequately in the UTM
(Universal Testing Machine) for tensile test, and several mechanical properties for aluminum can
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be determined from this testing. From the tensile test, we would like to acquire two mechanical
properties of the specimen which are strength and formability. An alternative testing we plan to
perform is the fatigue testing, this testing is proposed because the structure of our sample also
can be suitable for fatigue testing. Besides that, our specimens are also suitable for hardness
testing.

1.3 Objectives
The main objectives of this project are summarized in the following points:

i. To determine at least two of the mechanical properties of aluminium by conducting
mechanical lab testing using equipment available in the laboratory.

ii. To build the ability of organizing, leading, conducting and controlling material lab
testing experiment.

iii. To be able to analyse, evaluate and discuss results from mechanical testing of
material.

iv. To build up the ability of working in a team and to perform task within the given time.

v. To improve the ability of leading team work and also to be able to show obedience
and collaboration by doing each member of the team what is assigned to do.


1.4 Scopes
Aluminum is one of the most important and widely used metals in the transport, construction,
packaging and electrical sectors. Since aluminum is largely used in the industry, the main two
properties we will determine in this project by performing the tensile testing are:
Strength: Tensile strength (by tensile testing): also known as ultimate tensile strength is
the maximum stress under which the material can work before experiencing necking. This
property is very important because it ensure to avoid the material being used under load
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conditions that can lead to its failure. By comparing the ultimate tensile strength of
aluminium with the specification given by the design, we can know if it is safe to choose
aluminium for our design.

Stiffness: Modulus of Elasticity (by tensile testing): also known as Young Modulus is a
measure of the stiffness of a material. It describes how material responds to stress applied
or the materials resistance to elastic deformation. The larger the modulus, the stiffer the
specimen and the smaller the elastic strain that results from the applied stress. It is a
significant factor to be considered during the design parameter for computing the elastic
deformation of a specimen.
2.0 LTERATURE REVEW

Engineers are primarily concerned with the development and design of machines, structures
and materials and the creation of new and better machines that can improve the existing ones. Better
machine or material is one which is more economical in the overal cost of production and operation.
These products are often subjected to diffrence kind of forces and load. Hence it is important to know
the characteristeic of the material used and to design from which its deformation will not be
execessive and to avoid fracture of the material. The properties of materials under the action of forces
and deformations becomes an important engineering consideration.
The behavior of how a material reflect its relationship between its responce or deformation
while load and force applied is refered as the mechanical properties of the material. In other words
the properties that determine the behavior of engineering mats under applied forces. The most
significant mechanical design properties are stiffness, strength, hardness,ductility and toughness.
(Calister, 2011)This products also are made of basic materials that need to be tested in order to
measure the characteristics and behaviour of their substances. This type of tests is called material
testing. (Patel, 2014, para. 1). The mechanical properties of materials are verified by tests that
replicate as similiar as possible to the service environment. Factors which should be considered
include the nature of the applied load and its duration, as well as the environmental conditions.
Standard test methods have been established by such national and international bodies as the
International Organization for Standardization (ISO), with headquarters in Geneva, and the American
Society for Testing and Materials (ASTM), Philadelphia. ( Kenneth, 2014,para. 1)
Aluminium is the second most common use of material for structual compare to steel.
Structure made from aluminum is light and do not rust. It is commond to used for homeowner
projects. It is now used to replace steel in many industry due to it is lighter, morec orrosion resistant,
and a better conductor of heat and electricity. It is a good electrical conductor:it is ductile and can be
readily cast and machined. It has a face-centered cubic (FCC) structure and a density of 2990kg/m
3
.
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In this course, we had been given 3 aluminum rod specimens for us to conduct the
appropriate tests which could determine any two of the mechanical properties of the speciments. The
specimens are made of aluminum and having a dog boned shape. The specimens have an average
overall length of 10.00 cm; average distance between shoulders of 5.00 cm; average diameter/width
of gage section = 0.60 cm; and average diameter/width of grip section of 1.00 cm. In order to find out
the two mechanical properties of the specimens, we have decided to conduct a tensile test on the
specimens given. This is simply because the specimens meet all the criteria to undergo tensile test
and form the tensile test, we can produce yield strength for strength properties and also modulus of
elasticity for stiffness property.
Tensile test:
Tensile test, which also known as tension test, perhaps is the most basic type of engineering
mechanical test can perform on material for metals, polymers, composites, and others. Tension test is
simple, relatively cheap, and fully standardized.(Glosary of material testing, 2014, para. 9).
Tension test is commonly used to provide the most fundamental design information on the strength of
materials and is an acceptance test for the specification of materials. The key parameters that describe
the stress-strain curve obtained during the tension test are the tensile strength (UTS), yield strength or
yield point (y), elastic modulus (E), percent elongation (L%) and the reduction in area (RA%).
Toughness, Resilience, Poissons ratio () can also be found by the use of this testing technique.
(Gurbuz)

Test Specimen:

Small-size ASTM E8M Round Tension Test Specimen 3


In order to perform this test, 3 specimens as above are given. Tensile load is applied to the
specimen until it fractures. When the specimen is exposed to a tensile loading, the specimen will
undergo elastic and plastic deformation. Initially, the specimen will elastically deform giving a linear
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relationship of load and extension. The change in the gage length of the sample as pulling proceeds is
measured by extensometer. Elongation of the specimens and the load applied are recorded during the
test. The Universal Testing Machine (UTM) uses extensometers to measure the elongation of the
specimen up until necking, to measure the strain introduced on the specimen to calculate the
engineering stress and strain. Engineering stress is then plotted against the engineering strain to
acquire the tensile behavior of the specimens. Then the mechanical parameters that we search for can
be found by studying on this curve.

By past necking, the Universal Testing Machine (UTM) acquires the strain data from the
location of the crosshead. The load cell on the moving crosshead measured the vertical load applied
to the specimen. The diameter of the gage on the specimen is measured by using vernier calipers,
and from there the area is calculated by using Equation 1:

Equation 1

The engineering stress is a function of the force or load (N) applied and the original cross-
sectional area (m
2
) of the gage of the specimen. When a specimen is subjected to a tensile loading,
the metal will undergo elastic and plastic deformation. Initially, the metal will elastically deform
giving a linear relationship of load and extension. These two parameters are then used for the
calculation of the engineering stress and engineering strain to give a relationship as illustrated in
Figure 2 using Equations 2 and 3 as follow:

Equation 2



Equation 3



Where:











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During elastic deformation, the engineering stress-strain relationship follows the Hook's Law
and the slope of the curve indicates the Young's modulus (E) Equation 4:

Equation 4

The tensile loading continues, yielding occurs at the beginning of plastic deformation. The
yield stress, can be obtained by dividing the load at yielding (Py) by the original cross-sectional
area of the specimen (Ao) as shown in Equation 5.

Equation 5


Aluminum is having a FCC crystal structure and does not show the definite yield point but it
shows a smooth engineering stress strain curve. The yield strength therefore has to be calculated from
the load at 0.2% strain divided by the original cross-sectional area as follows Equation 6 :

Equation 6



The determination of the yield strength at 0.2% offset or 0.2% strain can be carried out by
drawing a straight line parallel to the slope of the stress-strain curve in the linear section, having an
intersection on the x-axis at a strain equal to 0.002 as illustrated in Figure 3. An interception between
the 0.2% offset line and the stress-strain curve represents the yield strength at 0.2% offset or 0.2%
strain.

Figure 2- Aluminum Engineering Stress and Strain Diagram Figure 3- Yield Strength 0.2% offset
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Pass yielding, continuous loading will cause to an increment in the stress needed to
permanently deform the specimen as shown in the engineering stress-strain curve. The specimen is
strain hardened or work hardened. The degree of strain hardening based on the behavior of the
deformed materials, crystal structure and chemical composition, which affects the dislocation motion.
FCC structure materials having a high number of operating slip systems can easily slip and create a
high density of dislocations. Tangling of these dislocations requires higher stress to uniformly and
plastically deform the specimen, therefore resulting in strain hardening.

As the load is continuously applied, the stress-strain curve will achieve its maximum point,
which is the ultimate tensile strength At this point, the specimen can withstand the
highest stress before necking occur. This can be seen by a local reduction in the cross sectional area
of the specimen generally observed in the center of the gauge length as illustrated in Figure 4. After
necking, plastic deformation is not uniform and the stress decreases accordingly until fracture. The
fracture strength ( fracture) can be calculated from the load at fracture divided by the original
cross-sectional area, Ao, as expressed in Equation 7. (T. Udomphol)

Equation 7


Figure 4- Local reduction in the cross sectional area




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3.0 METHODOLOGY

3.1 Small-size ASTM E8M Round Tension Test Specimen Procedures

3.1.1 The specimen was measured with the callipers to determine the diameter of the cross
section.
3.1.2 A gage length of 30.00 mm and was marked on the specimen so that the distance between
the two marks could be measured after the tensile test was completed.
3.1.3 Universal Testing Machine (UTM) was set up in such that zero force would apply on the
specimen. The load cell was zeroed to ensure that the software only measured the tensile
load applied to the specimen.
3.1.4 The specimen was loaded into the jaws of the load frame.
3.1.5 The axial and transverse extensometers were attached to the reduced gage section of the
specimen, the axial extensometer was ensured that it was correctly set when mounting it
to the gage and that the transverse extensometer was across the complete diameter of the
specimen.
3.1.6 The load was released, and the extensometers were zeroed using the software.
3.1.7 The test was started, and the specimen was loaded, resulting in a measureable of strain.
3.1.8 The crosshead speed was set to 0.9 mm/min (0.015 mm/mm/min) at a specified state
beyond yielding.
3.1.9 The data was compiled by using the software, and transferred into a spread sheet.
3.1.20 The test was continued until fracture, where the software stopped the moving crosshead,
and finished compiling the data.

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3.2 Project Activity
3.2.1 Task Assignment
- Patricio Aguilar and Ariff Hakimy : Literature Reviews
- Dionisio Miguel : Project Background.
- Estrella Matutina and Hoong Wei : Methodology

3.2.2 Scheduling

Date Time Agenda
22/05/2014 10.00 pm 1
st
Meeting
09/06/2014 10.00 pm 2
nd
Meeting
10/06/2014 10.30 am Lab Briefing Sessions
15/06/2014 10.00 pm 3
rd
Meeting
18/06/2014 10.00 pm 4
th
Meeting
25/06/2014 10.00 pm 5
th
Meeting
09/07/2014 10.00 pm Lab Progress Report Compile
10/07/2014 08.00 am Lab Progress Report Submission
11/07/2014 03.00 pm Lab Progress Report Viva/ Presentation
16/07/2014 03.00 pm Testing
18/07/2014 10.00 pm 6
th
Meeting
19/07/2014 10.00 pm Final Report Compile
21/07/2014 03.00 pm Final Report Submission


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3.2.3 Minute of Meeting
3.2.3.1 1
st
Meeting
Date: 22
th
May 2014
Venue: V3 Caf, UTP
Objectives:
1. Ice Breaking Session
2. To kick start the meeting of Engineering Material Lab Progress Report Activities
3. Assign tasks to group members

TIME AGENDA:
10.00 pm Meeting was commenced by Estrella Matutina
10.05 pm 1. Ice Breaking Session

- All members had introduced themselves

1. Estrella Matutina being the group leader explained the purpose of having this
meeting. She hoped we all could get along well and able to submit our work on
time.

2. Assigning Tasks :

- Patricio Aguilar and Ariff Hakimy will be responsible for the Literature
Reviews
- Dionisio Miguel will be responsible for the Project Background.
- Estrella Matutina and Wong Hoong Wei will be responsible for the
Methodology of the progress report.


11.00 pm Meeting adjourned.

3.2.3.2 2
nd
Meeting
Date: 9
th
June 2014
Venue: V3 Caf, UTP
Objectives:
1. To discuss the selection of the Lab Briefing slots.
TIME AGENDA:
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10.00 pm Meeting was commenced by Estrella Matutina
10.05 pm 1. Lab Briefing Slots
- After discuss with the all members, we decided to attend the Lab Briefing Slot on
Tuesday (10
th
July 2014) , 10.30am to 11.00am.



10.30 pm Meeting adjourned.

3.2.3.3 3
rd
Meeting
Date: 15
th
June 2014
Venue: V3 Caf, UTP
Objectives:
1. To discuss regarding the testing specimen provided.
2. To discuss the suitable mechanical properties of the specimen.
3. To discuss the suitable testing method to be conducted.
TIME AGENDA:
10.00 pm Meeting was commenced by Estrella Matutina
10.05 pm 1. The specimens were examined by all the members.

2. We conclude that the specimen is made of aluminium and dog-bone shaped.

3. We decided to find the strength and formability mechanical properties of the
specimen.

4. In order to find the two properties of the specimen, we will need to conduct the
tensile test.

5. We decided to meet the technician in charge of Tensile Testing, Mr Paris B Mohd
Said in Block 17 to acquire more information regarding the tensile test and the
specimen.

6. We will also search for the Standard Test of the specimen.

7.

- After discuss with the all members, we decided to attend the Lab Briefing Slot on
Tuesday (10
th
July 2014) , 10.30am to 11.00am.



11.10 pm Meeting adjourned.



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3.2.3.4 4
th
Meeting
Date: 18
th
June 2014
Venue: V3 Caf, UTP
Objectives:
1. To discuss regarding the testing specimen provided.
2. To discuss the suitable testing method to be conducted.
TIME AGENDA:
10.00 pm Meeting was commenced by Estrella Matutina
10.05 pm 1. After consulting with Mr Mr Paris B Mohd Said, we are able to the tensile test on
the specimen provided and we had also reserved a lab testing slot on week 9.

2. We had also acquired the ASTM Standard Test of Tensile Testing from the internet.
From the ASTM Standard Test, we know that our specimen belongs to the Small-
size ASTM E8M Round Tension Test.
11.10 pm Meeting adjourned.

3.2.3.5 5
th
Meeting
Date: 25
th
June 2014
Venue: V3 Caf, UTP
Objectives:
1. Remind members to submit their individual parts
TIME AGENDA:
10.00 pm Meeting was commenced by Estrella Matutina
10.05 pm 1. Estrella reminded us to submit our parts on 9/07/2014 for Lab Progress Report
Compilation.

2. Estrella hoped that we can all submit our part on time.
11.30 pm Meeting adjourned.


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3.3 Project Plan & Gantt Chart

NO Week Task
1.
1
(19-23/05/2014)
Meeting 1
Members introductory
2.
4
(9-13/06/2014)
Get the sample
Meeting 2
Review the lab briefing

3.
4
(14-15/06/2014)
Meeting 3
Set work plan
Interpret and analyse the standard of the
sample given
List and study the possible mechanical testing
of the material
Complete the Project Background part of the
lab progress report
4.
5
(16-20/06/2014)
Complete the Literature Review part of the
lab progress report
5.
6
(23-27/06/2014)
Meeting 5
Complete the Literature Review and
Methodology part of the lab progress report

6.
8
(7-11/07/2014)
Complete the lab progress report
Compile the lab progress report
Submission of the lab progress report
Lab progress report viva/presentation
7.
9
(14-18/07/2014)
Meeting 6
Meeting lab 2
Testing
Complete the Result and Discussion and
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Conclusion part of the final report.
Receive lab progress report feedback.
Final touch up of the final report
Compile the final report

8.
10
(21-25/07/2014)
Submission of the final report
Prepare for the group presentation and
individual VIVA


Gantt Chart :



Week 4
9-13
June
Week5
16-20
June
Week6
23-27
June
Week7
30-4
June/July
Week8
7-11
July
Week9
14-18
July
Week10
21-25
July
Sample
background

Standard
preparation

Literature
review

Methodology
Progress
report
submission

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Testing
Result and
discussion

Final report
submission

Viva
preparation



3.4 Equipment



Universal Testing Machine has two crossheads, one is adjusted for the length of the specimen and the
other one is driven to apply tension to the specimen.
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This machine has a proper capability for the test specimen being tested. It has 4 main parameters:
force capability which provides the force to break the specimen, sped, precision and accuracy.
4.0 REFERENCE

(ASTM), A. S. (2010). Standard Test Methods for Tension Tesing of Metallic Materials.
A simple Tension Test. (n.d.). Retrieved 07 09, 2014, from Experts Mind:
http://www.expertsmind.com/topic/theory-of-machines/a-simple-tension-test-919118.aspx
Calister, W. D. (2011). Material Science and Engineering . John Wiley & Sons (Asia) Pte Ltd.
Czichos, H. (2006). Springer Handbook of Materials Measurement Methods.
Favilla, S. (2010). Tensile Testing Laboratory.
Gurbuz, P. D. (n.d.). Tension Test. METU Department of Metallurgical And Material Engineering.
Instron. (n.d.). Featured Term - Tension Test. Retrieved 07 09, 2014, from Glossary of Materials
Testing Terms: http://www.instron.us/wa/glossary/default.aspx
Kenneth E. Hofer, J. (n.d.). Materials Testing. Retrieved 07 09, 2014, from Encyclopaedia Britannica:
http://global.britannica.com/EBchecked/topic/369090/materials-testing
Kevel, P. (2014). Machine design and industrial drafting.
T.Udomphol. (n.d.). Tensile Testing. Mechanical Metalhurgy Laboratory 431303.
Tensile Testing. (n.d.). Retrieved 07 09, 2014, from Wikipedia:
http://en.wikipedia.org/wiki/Tensile_testing