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L a b o ra t o ry 4
Torsion Testing
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Objectives
Students are required to understand the principles of torsion testing, practice their
testing skills and interpreting the experimental results of the provided materials
when failed under torsion.
To determine the maximum shearing stress, shear stress at proportional limit, shear
modulus or modulus of rigidity and relationships between torque and degree of
rotation of the tested materials.
Students are able to differentiate the ability of materials such as cast iron and brass
to withstand torque prior to torsion failure. Analysis and interpretation of the test
parameters obtained should be carried out in relation to the failure nature of each
material.
Students are capable of selecting materials for engineering applications associated
with torsion.
1. Literature review
In many areas of engineering applications, materials are sometimes subjected to torsion in
services, for example, drive shafts, axles and twisted drills. Moreover, structural applications such as
bridges, springs, car bodies, airplane fuselages and boat hulls are randomly subjected to torsion. The
materials used in this case should require not only adequate strength but also be able to withstand
torque in operation. Even though torsion test is not as universal as tension test and do not have any
standardized testing procedure, the significance lies on particular engineering applications and for the
study of plastic flow in materials. Torsion test is applicable for testing brittle materials such as tool
steels and the test has also been used to determine the forgeability of the materials by means of torsion
testing at elevated temperatures.
elastically deformed and the recovery of the specimen to its original shape is possible if the specimen
is unloaded. However, if a high degree of rotation is applied passing a proportional limit, the
specimen starts to deform plastically and will not return to its original shape when the input
handwheel is turned anti-clockwise.
The degree of rotation can be read out from two protractors, elastic and plastic range
protractors. First, an elastic range protractor scale is fitted on the input handwheel connected to the
input shaft of the gear box. This protractor scale provides an accurate reading of 0.1o and thus one
revolution represents 6o. A resettable revolution counter is fitted to the gearbox to record the overall
input revolutions. When the twisting moment is large, the second protractor scale is required for the
readouts in the plastic range of deformation. The second protractor is fitted onto the output shaft and
provides a reading of 1o with one revolution representing 360o.
9(1)
where J
G
r
L
is
is
is
is
is
is
r
L
9(2)
previously, the reduced effect of stress distribution in the thin-walled specimen is therefore beneficial
for the calculation of the stress. Within the elastic range of deformation, the shear stress can be
calculated according to equation 1
=
MT r
J
9(3)
For a solid cylindrical specimen, the polar moment J = D4/32, we can therefore determine
the shear stress as shown in equation 4
=
M T D / 2 16 M T
=
D 4 / 32 D 3
9(4)
For a tube specimen, the maximum shear stress at the peripheral of the tube can be calculated
from equation 5
=
where D1
D2
16 M T D1
( D14 D24 )
9(5)
Therefore, if the torque and the degree of rotation are known according to the experimental
result, the shear stress and the shear strain can be determined from equations 2 and 4. The obtained
information is then used for the construction of the graphical relationship between the modular shear
stress (16MT/aD3) and the shear strain (r/L) as illustrated in figure 7. The curve is somewhat similar
to those typical stress-strain curves tested under tension, giving elastic and plastic ranges with respect
to the torsional stress applied.
Nevertheless, the calculated shear stress according to equation 4 is only suitable for the
evaluation of the stresses in the elastic range. The plastic stress obtained from the shear stress-shear
strain curve is therefore larger than the real stress. Furthermore, in the case that there is a large
amount of plastic deformation involved, the length of the specimen is considerably changed, which
can result in the superposition of the longitudinal stresses on the torsional shear stresses. Even
Mechanical metallurgy laboratory 431303
T. Udomphol
though, the former is considered to be small and can be neglected, they might also affect the torsional
failure strain of the specimen. Nadai [3] has proposed the method for the calculation of the stress in
the plastic range from a known torque-degree of rotation curve as expressed in equation 6
u =
where Mmax
a
3M max
2a 3
9(6)
Figure 7: Relationship between modular shear stress and shear strain [2].
1.2 Types of torsion failures
Torsion failures are different from tension failures and normally provide little deformation or
elongation. The characteristic of the fracture surface is related to the state of stress at the point on the
bar surface, which can be described as shown in figure 8. It can be seen that the maximum shear
stresses exist along two planes, which are perpendicular to each other. One is perpendicular to the
longitudinal axis (yy) and another is aligned parallel to the longitudinal axis (xx). The principle
Mechanical metallurgy laboratory 431303
T. Udomphol
stresses 1 and 3 are inclined at 45o to the longitudinal axis and have their magnitudes equal to those
of the shear stresses. The principle stress 1 is tensile while the principle stress 3 is compressive.
The intermediate stress 2 is zero under torsion.
As mentioned previously, the characteristics of torsion fractures are influenced by torsional
and tensile forces. These result in two types of torsion failures; 1) ductile failure due to the shear
stresses and 2) brittle failure due to the tensile stresses. The former produces the fracture surface
along the plane of the maximum shear stress and more frequently normal to the longitudinal axis as
shown in figures a) and b). The latter exhibits the fracture planes normal to the directions of the
tensile stresses, which are 45o to the longitudinal axis. Figure 9 shows brittle and ductile fracture
surfaces observed from a driveshaft and a brass rod respectively failed under torsion. This means the
driveshaft failed under a brittle manner influenced by the tensile stresses while the ductile failure of
the brass rod was affected by the shear stresses. However, if the specimen fails into little pieces
where the fracture plane cannot be determined, the fracture in this case is considered to start along the
maximum shear stress parallel to the longitudinal axis of the specimen. In addition, it has also been
shown in a study, which has indicated that the fracture characteristic is associated with the hardness of
the tool steels. If the tool steel possesses the hardness values of higher than 720 VHN, failure is
expected to be influenced by tensile stress. Conversely, if the hardness of the tool steel is lower than
720 VHN, the shear stress is responsible for such a failure.
Figure 9: Fracture surfaces of a driveshaft and a brass-rod failed in brittle and ductile
manners under torsion.
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4. Results
Details
Cast iron
Brass
Table 1 Experimental results for torsion test of cast iron and brass.
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5. Discussion
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6. Conclusions
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7. Questions
7.1 Did cast iron and brass fail in different fracture manners? Explain.
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7.2 What are the differences between torsion and tension tests?
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7.3 Which engineering applications do you think that torsion test is vital? Give three examples.
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8. References
8.1 www.doitpoms.ac.uk
8.2 SM1/2 Torsion testing machine, TecQuipment Ltd 2000.
8.3 Dieter, G.E., Mechanical metallurgy, 1988, SI metric edition, McGraw-Hill, ISBN 0-07100406-8.
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