INDEX

EXP. NO. NAME OF EXPERIMENT Page No.

1. Stress- Strain characteristics of Mild Steel bar by UTM. 2

2. Double Shear Test. 8

3. Brinell/Rockwell hardness Test. 10

4. Young’s Modulus of given specimen. 14

5. Charpy/Izod Impact Test. 17

6. Torsion Test. 21

7. Test on springs. 24

8. Stress analysis by strain gages and stress concentration 26

Appendix – I 31

1
 EXPERIMENT -1

STRESS STRAIN CHARACTERISTICS OF MILD STEEL BAR BY UTM

Object:
To study the stress strain characteristics of mild steel by Universal Testing Machine

Equipment:
Universal testing machine, dial gauge, meter rule, dividers and scale, Mild Steel specimen

Theory:

In tension test of ductile metals, the properties usually determined are yield strength,
ultimate tensile strength, modulus of elasticity, percentage of elongation etc. For brittle materials
only compressive strength is determined.

The tension test is normally carried out in a Universal Testing Machine (UTM). The
specimen can be in the form of a rod or a plate. The dimensions of standard specimen can be
known from accepted specifications.

The following properties can be determined from the stress strain curve of the material:

1) Proportional limit: is that point on the stress strain curve at which the curve deviates from
linearity, i.e. from the relation
Stress = Young’s modulus x strain   = E

2) Elastic limit: is the point on the stress strain curve above which plastic deformation (that is
permanent deformation) starts.

3) Yield strength: is the stress required to produce a small amount of permanent or plastic
deformation.

In some materials such as mild steel, where there is occurrence of sharp yield point on the
stress-strain curve, the stress value at the lower yield point is taken as the yield strength.
In some materials like tor steel which do not have a sharp yield point, the offset yield
strength or proof stress is taken as the measure of the yield strength. This is the stress at
which a line drawn parallel to the initial portion of the curve, offset by a specified strain,
intersects.

The offset value is usually a strain of 0.002 (0.2% strain). The value of the yield strength
is of great importance in design calculations.

4) Tensile strength or ultimate tensile strength (UTS) is the maximum load divided by the
original cross sectional area of the specimen. U.T.S. corresponds to the peak or the
highest stress value in the stress-strain curve.

5) Ductility:
It is usually measured as percentage elongation in length or percentage reduction in area.
These measures of ductility are obtained after fracture, by keeping together the two broken
2
 parts of the specimen, and measuring the gauge length at fracture, and area of cross section
at fracture.

(L  L0 )
Percentage elongation in length  f x 100
L0
A  A0
Percentage Reduction in area  f x 100
A0
Where,
LO and AO are initial gauge length and initial area of cross section respectively.
Lf and Af are measured gauge length at fracture and area of cross section at fracture
respectively.

Description:

UTM serves for conducting tests in tension, compression, bending, Brinell hardness and
shear. The testing machine is operated hydraulically. Driving is performed with the help of
electric motor.

The machine essentially consists of two units, loading unit and control panel. The
specimen is tested or loaded on the loading unit and the corresponding readings are taken from the
dial fixed to the control panel. The main hydraulic cylinder is fitted in the center of the base and
the piston slides in the cylinder when the machine is under operation. A lower table is rigidly
connected to an upper cross-head by the two straight columns. This assembly moves up and
down with the main piston. The mechanical power drive of the upward and downward motion of
the movable cross-head consists of electric motor and of two worm gear trains connected to the
columns. Tensile test is conducted by fixing the specimen in between lower and upper crossheads
by the jaws inserts. Compression test is conducted by putting the specimen in between lower
table and lower crosshead. An elongation scale is also kept sliding, which is fixed between lower
table and the upper crosshead. The elongation indicating pointer is fixed to the lower crosshead.

The right side valve is a pressure flow control valve and left side valve is a return valve to
allow the oil from the cylinder to go back to the tank. Control panel also consists of
dynamometer; which measures and indicates the load on the specimen.

Before testing, adjust the pendulum weight according to the capacity test piece in order to
get the accurate range. Adjustment can be done as follows:

CAPACITY METHOD OF INCREASING LOAD

1/10th of max. capacity only pendulum
1/4th of max. pendulum + A
½ max capacity pendulum + A + B
Full pendulum + A + B + C

Adjust the corresponding range on the dial gauge with the range adjoining adjusting the
knob.

3
Procedure:

1) Mark the gauge length on the test piece.

2) Measure the diameter of the test piece at several sections by Vernier calipers and note
down the mean diameter.
3) Fix the specimen firmly to the jaws of the testing machine.
4) Mount the dial gauges on the specimen so that screw points engage with the center of
gauge marks at the extremities of gauge length.
5) Gradually increase the tensile load and note down the dial gauge corresponding to
different loads until the yield point is attained.
6) Note down the yield point corresponding to which the pointer (load) will suddenly stop
recording the load while the reading in the dial gauge moves on.
7) Remove the dial gauge from the specimen and continue loading until fracture occurs.
Measure the extension by means of dividers and steel rule. Load increases gradually
and attains a max value called ultimate load.

a = proportionality limit A = Yield stress

b = elastic limit
c = Yield point
d = Ultimate stress
e = Breaking stress

After reaching the ultimate load the needle of the dial moves back quickly and the specimen will
be broken at some load, which is lower than the ultimate load. It may also be noted that there will
be neck formation on the test specimen when the load starts falling.

8) Remove the fractured specimen from the machine and measure its diameter and the final
gauge length.
9) Plot the graph between stress vs strain and determine the limit of proportionality, yield
stress and Young’s modulus E.

Observations and Calculations:

Mean diameter, d =
Initial area of cross Ao =  d2/4 =
Gauge length = Lo =

4
S.No. Load (kg) Dial gauge reading Elongation stress strain
Initial Final L P/A L/Lo

5
Discussion:

Compare the experimental results with the theoretical values for mild steel, comment on
any reason for discrepancy, comment on any instrumental/experimental errors, area of
application.

Theoretical values:
Yield of mild steel = 250 N/mm2

QUESTIONS

1) Define Hooke’s law, Young’s modulus, stress, strain, yield stress, ultimate stress,
percentage elongation and percentage of reduction in area.
2) Define working stress and how it can be determined.
3) Draw (not to the scale) the hypothetical stress-strain relationship for mild steel.
4) Differentiate between True Stress and Engineering Stress.
5) Draw the sample true stress strain curve for mild steel.
6) What do you understand by proof stress?
7) Define ductility and brittleness.
8) Why this machine is called Universal Testing Machine.
9) Does the original gauge length depend on the original diameter of the specimen? If yes,
how?
10) Differentiate between Upper and Lower yield points.
11) Does the specimen fracture at maximum load? If not, why?
12) How does Mild Steel differ structurally from Cast Iron?

6
 EXPERIMENT – 2

DOUBLE SHEAR TEST

Object:
Determination of ultimate shear strength of mild steel specimen by double shear test.

Equipment:
Shear tool assembly, specimen to be tested, Vernier calipers, and compressive testing
machine.

Need and scope of the experiment:

For rivets in trusses, plate girders etc., mild steel and high tensile steels are used. Rivets
are subjected to bearing and shearing stresses. The behavior of the steel rod under shear is
investigated experimentally.

Procedure:
1) Find the diameter of the given rod with the help of Vernier calipers. Measure the diameter
of the specimen at three sections.
2) Depending on the diameter of the rod, select circular discs.
3) Place circular discs in the shear box and place the specimen passing through all the
circular discs.
4) Now keep the shear box assembly in the compression testing machine.
5) Turn the anvil of the machine until it touches the shear box.
6) Start the machine and open the inlet valve. Up to certain stage, load gradually increases
and thereafter starts receding.
7) Note the maximum reading on the dial gauge of compression testing machine. Let it be 'P'.
8) Observe the number of pieces into which the specimen is cut. The specimen breaks into 3
pieces i.e. the specimen is cut into two sections. Shear force is developed in the specimen
during loading is called double shear.
9) Shear strength can be calculated as below:
load(P)
Shear strength 
2 x Area of cross section of the specimen
10) Examine the nature of the failure of the specimen. The shear surface will be smooth.

7
Observations and Calculations:
1. Calculation of the diameter (Mild Steel) :

Least Count of Vernier Calipers =

S.No. M.S.D. V.S.D. M.S.D. + (V.S.D. x L.C.)

Average = mm
Average diameter of the specimen (d) = mm
π
Area of the specimen  d 2  mm2
4

2. Shear Strength:

Specimen S.No. Ultimate Load Ultimate Shear Strength

particulars (P) (kN) (N/mm2) (P/2A)
1

Mild steel 2

Average =

Result:
Average ultimate shear strength of given mild Steel specimen = N/mm2

QUESTIONS

1) What is meant by double shear?

2) In what manner material fails in double shear?
3) What is the capacity of a compression testing machine you have used?
4) Compression testing machine is electrically operated or hand operated or both.
5) Why generally, compression testing machines are having very large capacity?
6) What is ultimate shear stress?
7) Define Hooke's law using shear stress?
8) What do you measure on dial of compression testing machine?
9) What are you determining in Double shear test?

8
 EXPERIMENT - 3

BRINELL HARDNESS TEST

Objective:
To determine the hardness of a given material by Brinell's hardness testing machine.

Equipment:
Brinell's hardness testing machine, microscope and specimen

General theory for hardness test:

Hardness may be defined as resistance of the metal plastic deformation by indentation.
However, the term may also refer to stiffness or temper or to resistance to scratching, abrasion or
cutting. Mainly there are three types of hardness tests.
1) Indentation test
2) Abrasion or wear test
3) Scratch test.
Of these the most important tests are based upon the principles of indentations and are the
Brinell's, Rockwell and Vickers's hardness tests. In each case the material under test is indented
by another body to which a static load is applied.

Theory for Brinell hardness test:

In this test, a standard hardened steel ball is pressed into the surface of the specimen by
gradually applied load, which is maintained in the test piece for a definite time. The indentation
or the impression so obtained is then measured by a micrometer microscope. The Brinell's
hardness number is found out by the equation given below. The Brinell hardness number gives
the comparative hardness of a body.
Here,
P = the load in Kg
D = diameter of the ball in mm
d = the diameter of indentation in mm
Y = the depth of indentation in mm
Y = (D/2) - ( D / 2) 2  (d / 2) 2

The Brinell's hardness number is given by

P
B.H.N. =
Sperical area of indentation

Where, Spherical area of indentation = area of projection on the ball circle

= DY
D D d  
2 2

=  D       
2  2   2  


9
Spherical area of indentation =
D
2

D  D2  d 2 
Substituting for spherical area
2P
B.H .N . 
 D (D  D2  d 2 )
If the ball diameter or the pressure is varied for indentation in the same material, the
hardness number will be different. For the purpose of comparison of results it is therefore
necessary to specify diameter and the pressure applied during the test, further it is found that the
time during which the load is maintained is also important.

Extensive work was carried out by 'Mayer' to establish the effects of variation of ball
diameter and load which leads to the conclusion that for similar indentation in the material.
P/D2 = Constant
For the standard conditions given to hard materials
P/D2 = 3000/100 = 30
Hence, for a comparative test using a ball diameter D1 mm. We must apply a load P1 such that

P1 P
2
 2  30 or P1 = 30 D12
D1 D
According to ASTM specifications, a 10mm, diameter ball is used for indentation. Lower
loads are applied for measuring hardness of soft materials and vice versa.

Loads and indenters for Brinell hardness test on various metals:

Load in Kg
Ferrous materials Non Ferrous materials
Ball diameter
Steel & Iron Brass Aluminum Soft bearing
30 D2 10 D2 5 D2 metals 2.5 D2
10 mm 3000 1000 500 250
5 mm 750 250 --- ---
2.5 mm 187.5 ---- --- ---

Procedure:
For the Brinell hardness test, the surface of the specimen of which the impression is to be
made should be flat. The surface on which the impression is made as well as the surface in contact
with the support should be smooth, clean, dry and free from oxide scales and pits. The standard
indenters supplied may only be used for hardness up to 450 HB. For carrying out test the
following procedure should be adopted very carefully. Any negligence may lead to spoil the
indenter as well as the machine.

1) Select the proper diameter of ball and put proper weights on the weight hanger such that
the combination will suit the materials being tested. There are ten loose weights each
weight is 250 kg, the initial weight applied by the main lever is 250 kg, and the hanger,
weight of shaft, and bottom weight is equivalent to 250 kgf (total 3000 kg).

10
 2) Start the motor by pushing the green button of the starter and allow the oil to circulate for
few minutes. Operate the hand lever form A to B several times to raise and lower the
weights in order to eliminate the air from hydraulic system.
3) Keep the hand lever at position at A.
4) Start the motor and wait until the weight hanger reaches its top position.
5) Place the specimen securely on testing table.
6) Turn the hand wheel in clockwise direction, so that the specimen will push the indenter
and will show a reading on dial gauge. The movement is continued until the long pointer
will stop at 'O' and small pointer at red dot, when the initial load of 250 kgf is applied. If
little error exists the same can be adjusted by rotating the outer ring of dial gauge.
7) Turn the hand lever from position A to B so that the total load is brought into action.
8) When the long pointer of dial gauge reaches a steady position the load may be released for
normal testing, or may be maintained up to 15 seconds for accurate work. For releasing the
load, take back the lever to 'A' position. The weights are lifted off and the indicator will
come to rest at the required depth reading. Thus only the initial load is remaining active.
9) Turn back the hand wheel and remove the specimen.
10) For accurate tests, measure the diameter of impression by Brinell microscope and find out
the Brinell hardness number by calculation.
11) Carry the same procedure for further specimens.

Precautions:
1) The diameter of each indentation shall be measured in two directions at right angles to
each other and the mean value of the two readings shall be used for the purpose of
determining the hardness number.
2) The test load is maintained for a period of 15 seconds for brass, and 30 seconds for steel.
3) The center of impression shall not be less than two and a half times the diameter of the
impression from any edge of the test piece.
4) The thickness of the test piece should be such that no marking showing the effect of the
load shall appear on the underside.
5) This test should not be used for steel with hardness exceeding BHN 450 as no dent
(impression) will be left on the surface.
6) It is desirable to conduct the test at a temperature of 27o+2o as per I.S. Code.

Diameter of load
d1 d2 Average 'd'
S.No. Material Indenter applied BHN
(mm) (mm) (mm)
D(mm) P (Kgf)
01 Steel
1

02 Brass
1

11
Result:
Average Brinell's Hardness Number of steel =

Average Brinell's Hardness Number of Brass =

QUESTIONS

1) Define hardness of a material.

2) Why is hardness test required to be performed? Or what is the importance of hardness test?
3) Discuss the effect of surface roughness and oily surface of a specimen on the hardness
number.
4) Show by drawing figure, how to measure depth and diameter of indentation. How will you
find out hardness number from this data?
5) State the type of Hardness testing machine used. State the principle on which this machine
is working.
6) For which type of materials, hardness test is recommended.
7) What type of indenter generally is used?
8) How, the data obtained from the test result will be useful in the field?

ROCKWELL HARDNESS TEST

Objective: To determine the Rockwell hardness for the given metal specimen.

Equipments Required:
1. Rockwell Hardness Testing Machine.
2. Metal Specimen.

Description:
Hardness may be defined as resistance of metal to plastic deformation usually by
indentation. However the term may also refer to stiffness or temper or resistance to scratch,
abrasion or cutting. There are three general types of hardness measurements depending upon the
manner in which the test is conducted.

1. Scratch hardness measurement.

2. Rebound hardness measurement.
3. Indentation Hardness measurement.

In scratch hardness method the materials are rated on their ability to scratch one another
and mineralogists use it. In rebound hardness measurement, a standard body is usually dropped on
to the material surface and the hardness is measured in terms of the height of its rebound. The
general means of judging the hardness is the resistance of a material to indentation.
Indentation hardness may be measured by various hardness tests such as Brinell, Rockwell, etc.
Rockwell hardness testing differs from Brinell testing. In Rockwell testing, the indenters and
loads are smaller and therefore the resulting indentation on the specimen is smaller and shallower.
Rockwell testing is suitable for materials having hardness beyond the scope of Brinell testing.
Rockwell testing is faster as compared to Brinell testing, because the diameter of the indentation
need not be measured. The Rockwell machine gives arbitrary direct reading, Unlike Brinell
testing, Rockwell testing needs no surface preparation (Polishing) of the specimen whose
hardness is to be measured.
12
There are two scales on Rockwell testing specimen. i.e B scale and C scale. B scale uses a steel
ball indenter where as a diamond cone penetrate is employed for measuring Hardness on C scale.
B scale is for testing materials of medium hardness such as low and medium carbon steels in the
annealed condition. The working range of this scale is from 0 to 100. C scale is used for testing
materials harder than B-100. C scale is commonly used for testing the hardness of alloy cast irons.
In Rockwell hardness testing, the minor load for all cases is 10 Kg. whereas major loads
for scales C and B are 150 Kg and respectively, including minor load.

Test requirements:

1. The test should be carried out in an ambient temperature of 20 o+2o C in temperate climate
and 27o+2 o C in tropical climates.
2. The testing machine shall be protected throughout the test from shock and vibrations.
3. The test piece shall be placed on a rigid support. The contact surfaces shall be clean and
free from foreign matter. (Such as oil and dust)
4. The thickness of the test piece shall be at least 8 times the permanent indentation of depth.
No deformation shall be visible at the back of the test piece after the test.
5. The distance between the centers of the two adjacent indentations shall be at least 4 times
the diameters of the indentation and the distance from the centre of any indentation to the
edge of the test piece shall be at least 2.5 times the diameter of the indentation unless
agreed otherwise.

Precautions:

1. Successive impressions should not be superimposed on another nor be made too close
together when making hardness determinations.
2. Nor should a measurement be made too close to the edge , or on a specimen so thin that the
impression comes through the other side.
3. Small irregularities, dirt, and scale should be avoided because of the great sensibility of the
Rockwell test.

Procedure:

1. Test piece is placed upon the machine. The dial may be showing any reading.
2. Hand wheel is turned; thereby raising the test piece up against the steel ball indenter till the
needle of the small dial is against the red mark. This applies minor load.
3. Major load is applied by pressing the crank provided on the right hand side of the machine.
Time is given as 30 sec so as to make the load reach specimen fully.
4. When the penetration is completed, the crank is turned in the reverse direction thereby with
drawing the minor load but the leaving the major load applied.
5. The pointer moves further and becomes stand still. This reading is taken as Rockwell
Hardness Number – C scale.( HRC)
6. Hand wheel is rotated and the test piece is lowered.

13
 EXPERIMENT - 4

DETERMINATION OF YOUNG’S MODULUS USING SIMPLY SUPPORTED

BEAM SETUP

Objective:
Determination of the Young's modulus of a given material by conducting test
on simply supported beam and verification of Maxwell’s reciprocal theorem.

Apparatus:
Simply supported beam, scale, dial gauge, hanger and weights.

Formulae:
Concentrated load at center and deflection measured at quarter span.
W

A C D B
l/2 l/4
Span = l

Deflection is measured at D is given by

11 Wl 3
YD  x
768 EI
Procedure:
1) Measure the width and depth of given beam (steel or wood) by Vernier calipers.
2) Measure the distance between the two supports (span) with a scale.
3) Set the dial gauge at 'D' and adjust its value on the outer ring to zero by turning
it.
4) Find the weight of the hanger and keep it at the center of the beam.
5) Find the deflection in dial gauge.
6) Increase the weight on the hanger and find out the corresponding deflection.
7) Find the deflection while unloading also. Get the mean of deflections found in
step 6 and 7.
8) Draw a graph between load on y-axis and deflection on x-axis.
9) For verification of Maxwell’s reciprocal theorem, interchange the loading and
dial gauge positions and repeat the above procedure.

Observations:
Breadth of Beam (b):

Least count of Vernier calipers =

14
 M.S.D. + (V.S.D.x L.C.)
S.No. M.S.D. V.S.D.
(mm)

Average breadth of beam (b) = mm.

Depth of the beam (d):

Least count of Vernier calipers =

M.S.D. + (V.S.D.x L.C.)

S.No. M.S.D. V.S.D.
(mm)

Average depth of the beam (d) = mm

bd 3
Moment of inertia, I   mm 4
12

Load (W) Dial gauge reading @ D Deflection @ D =

S.No. Mean
@ C in Kg Loading Unloading mean x L.C.(mm)
1
2
3
4
5
6
7
8

15
Graph:
Draw a graph between load and deflection. From Graph find the Young’s
modulus of the given material.

Result:

Young's modulus of the given material ESteel = N/mm2

EWood = N/mm2

QUESTIONS

1) What is meant by beam?

2) Draw a neat sketch of experimental set-up and show position of load applied on
the beam.
3) How deflection is measured?
4) How will you determine modulus of Elasticity of a beam material from load-
deflection curve?
5) Compare your result with the standard modulus of elasticity.
6) What is meant by simple supported beam?
7) Define the terms concentrated load and distributed load.
8) Name the type of internal stresses for which a transversely loaded beam is
subjected.
9) What is meant by pure bending?
10) State Maxwell’s reciprocal theorem.

16
 EXPERIMENT -5

CHARPY IMPACT TEST

Object:
Determination of the energy absorbed and impact strength of steel using Charpy
impact testing machine.

Need and scope of the experiment:

The necessity for impact tests has arisen due to the failure of materials used in
high speed machinery under repeated forces of impulsive character, even when such
material has shown satisfactory strength and deformation in a static tensile test.
Various forms of impact test has been devised, of which Izod impact test is the only
one to try to determine the imperfections in material likely to fracture by "shock".
Although the Izod impact test has long been used as the standard form of test for
checking the brittleness of metals, the need has arisen for test at elevated and subzero
temperatures. For this purpose the CHARPY IMPACT test is more convenient. The
specimen need not be clamped and it can be quickly positioned without significant
change of temperature.
The standard shape of the test specimen is as shown in fig, which is being tested
in bending with a standard notch in this Charpy test. Under this test, the notch on the
specimen sets up stress concentrations, which ensures that fracture, does occur.

Apparatus:
(i) Charpy impact testing machine
(ii) Charpy specimen of 10mm x 10mm. square cross section and 55mm length,
with a V-notch 45o angle, 2mm deep and 0.25 mm root radius along the middle of the
length. For a U-notch specimen, the dimensions are 5mm deep, 2mm width and 1mm
root radius. The specimen is kept as a simply supported beam in horizontal position
and loaded behind the notch by the impact of a heavy swinging pendulum (16 kg).
The angle of drop of pendulum is 14 o. The impact velocity is approximately
5.3465m/sec. The specimen bends and fractures at high strain rate.

Procedure:
Without the specimen in the machine, swing the pendulum to ensure free
movement and to check the scale. For this lift the pendulum to its starting position by
the aid of hand crank and release the pendulum by lifting the spring loaded safety
handle in anti-clock wise direction and turning it simultaneously as the pendulum
swings it carries the pointer on the scale with it and leaves back the pointer when it
returns. Note the reading on the scale against the pointer, which gives the initial error
if any. Now lift the pendulum again to its starting position. Keep the specimen on the
supports of the machine such that the notch portion of the specimen is away from the
striking edge as shown in fig. Release the pendulum as before. The hammer strikes

17
the specimen breaks it and moves the needle in clockwise direction. Note the reading
against the pointer. The difference of the two readings gives the energy absorbed by
the specimen.
Energy absorbed N-m
Charpy value or impact strength = --------------------------------
C/S. area at notch (mm2)

Observations:
Specimen I:
Breadth (b):
Least count of Vernier calipers =

M.S.D. + (V.S.D.x L.C.)

S.No. M.S.D. V.S.D.
(mm)

Average breadth (b) = mm.

Depth (d):

M.S.D. + (V.S.D.x L.C.)

S.No. M.S.D. V.S.D.
(mm)

Average depth (d) = mm

Specimen II:
Breadth (b):
Least count of Vernier calipers =

M.S.D. + (V.S.D.x L.C.)

S.No. M.S.D. V.S.D.
(mm)

Average breadth (b) = mm.

18
Depth (d):

M.S.D. + (V.S.D.x L.C.)

S.No. M.S.D. V.S.D.
(mm)

Average depth (d) = mm

S.No. Initial Energy Final Energy (J) Energy absorbed

(J) By specimen (J)
1
2
3

Calculations:
Specimen I:

Specimen II:

Results:
Specimen I:
Energy required to fracture the specimen, U = J
Charpy value = Nm/mm2

19
 QUESTIONS

1) What is strain energy?

2) The machine on which you have performed test for measuring energy required
to fracture the specimen is _____.
3) How do you measure the toughness of a material?
4) Why notch is prepared in the specimen?
5) Draw a neat sketch of specimen for Charpy impact test.
6) How will you determine Charpy impact value for a given material?
7) Will the energy require for fracture the specimen remains same by increasing or
decreasing the height of hammer?
8) What is instantaneous stress?
9) What is the difference between impact produced by gradually applied load and
by suddenly applied load on a body or a specimen?
10) Why impact test is required for a material?
11) What property of metal does the impact test measure?
12) What is the difference between Izod’s and Charpy’s tests?

IZOD IMPACT TEST

Objective: To determine the impact modulus of the given specimen by izod test.

Equipments Required:

1. Impact Testing Machine with IZOD arrangement.

2. Specimen
3. Vernier caliper.

Description;

Many machines or machine components are subjected to a suddenly applied

load, which is called as impact blow. For determining the suitability of a material to
resist the impact blow. For determining the suitability of a material to resist the
impact, IZod and charpy test are carried out.

20
 EXPERIMENT – 6
TORSION TEST
Objective:
To find the modulus of rigidity of a given specimen.
Equipment:
Torsion testing machine, specimen, Vernier calipers and metal rule.
Specimen for the test:
The specimen should be of such size as to permit the desired strain
measurement to be made with sufficient accuracy. It should be of such properties that
the stress due to gripping ends does not affect the portion of the specimen on which
measurements are made. The ends of the specimen should be such that they can be
securely gripped without any local failure at the grips.
Theory:
For a shaft subjected to a torque ‘T’, the relation between torque, shear stress
and angle of twist is given by
T f G
 s 
IP R L
Where T = torque in N-mm
Ip = polar moment of inertia of specimen in mm4
fs = shear stress at a radius R of the specimen, N/mm2
R = radius of the shaft in mm
G = modulus of rigidity in N/mm2
 = angle of twist in radians (1 degree = 0.01745rad)
L = length of the shaft in mm
T L
Hence, G  x
Ip 

For a solid circular shaft of diameter‘d’, Ip =  d 4/32.

For how circular shaft of external diameter D and internal diameter‘d’,
Ip =  (D4 - d4) / 32
Procedure:
1. Measure the diameter of mild steel specimen using vernier calipers.
2. Measure the gauge length of the specimen.
3. Hold the specimen in between the plates with a dog holder in position by
rotating the hand wheel till the indication dial is just on the point showing the
action of the pointer.
4. Adjust the circular main scale with zero of the vernier scale.

21
5. Apply an increasing torque to the specimen in suitable increments by turning
the hand wheel.
6. Continue the test and record the corresponding readings of torque and angle of
twist, until fracture occurs.
Plot a graph of torque vs angle of twist and determine the Modulus of Rigidity.

Observations:
Diameter of the specimen ‘d’ =
Gauge length ‘L’ =
Polar moment of inertia Ip =

Angle of twist  in Angle of twist  in Torque(T)

S.No.
degrees radians Kg-cm

22
Precautions:
1) The test piece should, as far as possible, be straight and of sufficient length to
provide the desired length between the grips.
2) Any straitening should be done by hand without damaging the test piece.
3) The free length between the grips should be provided strictly to I.S.code:
1717-1971.
4) If the failure of the specimen takes place with in twice the diameter of the
grips, the test should be considered as invalid and should be repeated.
5) The surface of the test piece after failure should be examined so that it is free
from cracks.

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 EXPERIMENT – 7

TEST ON SPRINGS

OBJECTIVE
To determine the Shear Modulus (or) Modulus of Rigidity of the given spring
material.
APPARATUS
Spring Testing Machine 2000 kgf
PROCEDURE:
1) Note the particulars of the spring such as mean diameter of the spring, mean
diameter of the spring wire, number of turns.
2) Place the spring below the platon in such a way that the axis of the spring is
truly vertical and exactly below the centre of the loading frame. Rotate the
handle of the loading frame and bring down the proving ring to touch the spring
and rest over it without applying any load. Any further rotation of the hand
wheel causes application of load on to the spring.
3) Fix the deflection measuring dial gauge below the bottom plate of the proving
ring. Pull down the needle of the dial gauge and leave it and ensure that all times
the deflection gauge shows the same reading.
4) Note the initial reading of the deflection gauge and the calibrated value of the
proving ring (i.e., 1 div = _____ kg).
5) Apply the required amount of load by rotating the hand wheel and bringing the
proving ring dial needle to the calibrated reading. Note the deflection gauge
reading.
6) Repeat step (5) by increasing the load on the spring. Take at least 15 sets of
readings.
PRECAUTIONS:
1. Load should be applied on the spring without any eccentricity.
2. Deflection gauge needle should touch the bottom plate of the providing ring and
should be vertical.
3. Gently apply the load by rotating the hand wheel, without any vibrations either in
the spring or in the loading frame.

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OBSERVATIONS:
Mean radius of the spring, R = cm
Number of turns in the spring, n =
Mean diameter of the spring wire, d = cm
Modulus of rigidity of the given spring, C = 64 W R3 n ,
d4
where, W – Load applied on the spring (kg)
- Deflection of the spring (cm)
Initial deflection gauge reading = mm

S.No. Applied load Deflection Net Shear

(kg) Gauge reading deflection Modulus, C
(mm) (cm) ( x 105kg/cm2)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.

Average C = x 10 5 kg/cm2

RESULTS:
Average Shear Modulus of the given spring, C = x 10 5 kg/cm2

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 EXPERIMENT – 8
STRESS ANALYSIS BY STRAIN GAGES AND STRESS CONCENTRATION
Objective:
a) Determination of bi-axial state of stress at a point on the surface of an
object.
b) Determination of stress concentration around notches and openings.
c) Evaluation of material properties for known load and deflection.
d) Use of transducers such as load cell and accelerometer.
Apparatus: Strain measuring instrument, scale, soldering iron, abometer, load cell.
Materials: Strain gages, acetone, adhesive, load cell, plate with hole, beam specimen.
Procedure:
1) For fixing the strain gage on any surface, first the surface of the specimen
is to be polished carefully and then cleaned with acetone. The gage is
applied on the cleaned surface with the help of epoxy cement or cellulose
nitrate by pressing it gently.
2) The adhesive is allowed to cure for 24 hours. The insulation of the gage to
the specimen is checked. The continuity of the gage wire is also checked.

A. Determination of material properties.

Objective: To measure the modules of elasticity (E) and the Poisson’s ratio of a
material from the strain records of a cantilever beam. The experimental set up is as
shown in Fig. 9.1

Apparatus: As mentioned above

Materials: Strain gages, Beam Specimen.

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Procedure:
1) Connect the gages to the strain recorder through channel selector.
2) Set the gage factors on strain recorder
3) Set the initial reading to zero or note the initial readings.
4) Load the specimen at least at three stages.
5) Note the final readings.

Observations:
Record the strain increments in Table. 9.1
Load Gage Gage Initial Final Increase/ Remarks
No. factor reading reading decrease
1 1
2
2 1
2
3 1
2
Results: Gage Factor – Gage A:
Gage B:
Length of cantilever (l) =
Width of Beam =
Depth of Beam =
Second moment of area (I) =
Bending moment =
Bending stress (  x ) =
x
Modulus of elasticity (E) = =
x
x
Poisson’s ratio (  ) = =
y

Discussions: Discuss in respect to (a) Usage and advantages of electrical strain gages
over other type; (b) Effect of temperature etc. on results

Precautions: As relevant to experiment

B. Determination of stress concentration factor by strain gages.

Objective: 1) Determination of material constants.
2) Evaluation of stress concentration factor.

Apparatus: As mentioned above

Materials: Strain gages, Application kit, Plate specimen with hole.

Procedure: 1) Fix the gage and complete the connections.

2) Load the specimen and record the strain in Table. 9.2

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 Table 9.2

Specimen Gage No. Gage Initial Final Increase/ Remarks

factor reading reading Decrease
I 1
2
3
4
II 1
2
3
4

Results:
Resistance = Load =
Gage factor =
Gage length =
Type of wire =
1. Material properties:

E = Modulus of elasticity =
 = Poisson’s ratio =

2. Stress Concentration Factor

 average =
 actual =
K (SCF) =

Discussions: Discuss in respect to (a) Stress concentration factor; (b) Material

properties

Precautions: As relevant to experiment

C. Calibration of load cell.

Objective: Load cells are used in series with the applied force to measure the force
directly. The objective of this experiment is to calibrate such load cells against known
loads.

Apparatus: Strain measuring instrument.

Materials: A ring of brass with gages fixed in the inside and outside edges as shown
in Fig. 9.2, strain gages

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Procedure: 1) An approximate working range is estimated from theoretical
considerations.
2) At least five known load levels are to be used to calibrate the cell.
3) Data are to be recorded in the Table. 9.3

Table 9.3

Load Gage A Gage B Increment Increment A B

In A In B

Discussions: Discuss in respect to (a) Type of load cells; (b) fixing of gages.

Precautions: As relevant to the experiment performed

29
Questions:
1. What is load cell?
2. What is meant by calibration?
3. What are the different types of strain gages generally used?
4. What is the principle on which electrical resistance strain gages work?

30
 Appendix – 1: Electrical Resistance Strain Gages
Introduction

A wire or a foil called strain gage is bonded to specimen (Fig. A1) such that the
deformations of the specimen surface and the gage are same. Due to the changes in
length and cross sectional area the resistance of the gage changes. The change in
resistance, which is measured by the principle of Wheatstone bridge, is related to
strain through a Gage Factor (G).

 R / R 
G = Gage Factor = (1)

Where R is the resistance of the gage,  is the strain and R is the change in
resistance of gage due to strain  .

Theory

Two leads from the strain gage are connected to the arm AB of the Wheatstone bridge
(Fig. A2). If the voltage across AB is measured,

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 E
Current through R1  I AB 
( R1  R2 )

ER1
Voltage drop across R1  EAB 
( R1  R2 )

Where E is the voltage drop between A and C

ER2
The change in the voltage due to R1  E BD  R1
( R1  R2 ) 2

ER2
Hence the voltage drop in B relative to D is = R1
( R1  R2 ) 2

R1 / R1
According to the definition of gage factor (G) =
1
R1R2
And the voltage drop in rewritten as EBD  GE 
( R1  R2 )2
If four similar gages are placed in four different arms of Wheatstone bridge, it can be
shown that

 RR RR RR RR 

EBD  GE  1 2 1 2  1 2 2 2  3 4 3 2  3 4 4 2 
 ( R1  R2 ) ( R1  R2 ) ( R3  R4 ) ( R3  R4 ) 

The physical interpretation of the preceding equation is often utilized to increase the
sensitivity of measurement. For example, if a short column is subjected to an axial
load, two of the four gages may be aligned axially and connected to the arms (1) and
(4) whereas other two gages may be applied in transverse direction connected to the
arms (2) and (3).  1   4   ,  2   3   , measures the unbalance.

For dynamic analysis the voltage change is measured directly on the oscilloscope. But
for static analysis a more accurate method of ‘Null Balance’ is achieved with the help
of a potentiometer across BD (Fig.A2).

Precautions

There are several factors, which influence the accuracy of strain gage measurements
and precautions must be taken to compensate the effects. Most important amongst
there are
1) Temperature
2) Gage Current
3) Time
4) Adhesives
5) Humidity

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Material Properties

To determine the properties such as modulus of elasticity and poison’s ratio of

particular material, flexural specimens made out of such material may be tested. Fig.
9.1 shows one such specimen used for determining the material properties. A
cantilever beam specimen is loaded at its tip and strain gages are used in a location
closer to support, wherein appreciable strain can be obtained due to bending. From the
gage position, bending stress is evaluated for a known loading condition. The ratio of
computed stress to the measured longitudinal strain will be in the modulus of
elasticity. The negative of the ratio of lateral strain to longitudinal strain is defined as
poison’s ratio.

Calibration of Load Cell

One of the potential uses of strain gages is in the calibration of load cells. Load cells
are the elements used in series with the applied force to measure the force directly.
Strain gages are fixed in the locations of a ring load cell as shown in fig. Strains are
calibrated against as known loads. An approximate range is estimated from theoretical
considerations and the measured strain values are compared for a check.

Stress Concentration

Formulae from strength of materials permit us to compute the stress distribution

across a cross section of a member subjected to axial force, bending moment, shear
and torsion. But if the cross section changes abruptly or if there are some irregularities
such as a hole or a notch, stress distribution changes locally to conform to the
boundary condition (Fig. A3). In most of these cases there is marked increase in local
stresses.

Actual stresses in the vicinity of these irregularities may be analysed only by exact
method of the theory of elasticity and that too for comparatively simpler cases. For
practical applications, actual stresses at the stress concentration regions are
determined experimentally for a large number of specimens with varying geometric
parameters and materials. Results are represented in graphical forms.

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