MATERIAL TESTING LAB I

LAB MANUAL

1. STUDY OF UNIVERSAL TESTING MACHINE (UTM)

Aim :
To study the various parts and working of Universal Testing Machine.
General :
The Universal Testing Machine is so named as it can test almost all the tests in the Strength
of Materials laboratory except impact test on metals. The tests conducted in UTM are :
1. Tension test
2. Bending and deflection test
3. Compression test
4. Shear test and
5. Hardness test.
The UTM is available in different capacities viz., 100 kN, 200 kN, 400 kN, 600 kN, 1000
kN, 2000 kN and 3000 kN.
Principle of Operation :
Operation of the machine is by hydraulic transmission of load from the test specimen to a
seperately housed load indicator.
Load is applied by a hydrostatically lubricated ram. Main cylinder pressure is transmitted
to the cylinder of the pendulum dynamometer system housed in the control panel. The cylinder
of the
dynamometer is also of self-lubricating design. The load transmitted to the
cylinder of the dynamometer is transferred through a lever system to a pendulum.
Displacement of the pendulum actuates the rack and pinion mechanism which operates the
load indicator pointer and the autographic recorder. The deflection of the pendulum represents
the absolute load applied on the test specimen. Return movement of the pendulum is effectively
damped to absorb energy in the event of sudden breakage of a specimen.
It consists of the following units :
1. Straining unit
2. Control panel
3. Power pack
4. Hydraulic controls
5. Load indicator system
6. Pendulum Dynamometer

7. Autographic Continuous Roll Load - Elongation Recorder

1. Straining unit :
This consists of a hydraulic cylinder motor with chain and sprocket drive and a table
coupled with the ram of the hydraulic cylinder, mounted on to a robust base. The cylinder and
the ram are individually lapped to eliminate friction. The upper cross-head is rigidly fixed to the
table by two straight columns. The lower cross-head is connected to two screwed columns
which are driven by a motor. Axial loading of the ram is ensured by relieving the cylinder and
ram of any possible side loading by the provision of ball seatings. An elongation scale, with a
minimum graduation of 1 mm, is provided to measure the deformation of the
specimen.
Tension test is conducted by gripping the test specimen between the upper and lower crossheads. Compression, transverse, bending, shear and hardness tests are conducted between the
lower cross- head and the table. The lower cross-head can be raised or lowered rapidly by
operating the screwed columns, thus facilitating ease of fixing of the test specimen.
2. Control panel :
The control panel consists of a power pack complete with drive motor and an oil tank,
control valves, a pendulum dynamometer, a load indicator system and an autographic recorder.
3. Power pack :
The power pack generates the maximum pressure of 200 kgf/cm2. The hydraulic pump
provides continuously non-pulsating oil flow. Hence the load application is very smooth.
4. Hydraulic Controls :
Hand operated wheels are used to control the flow to and from the hydraulic cylinder. The
regulation of oil flow is infinitely variable. Incorporated in the hydraulic system is a regulating
valve, which maintains a practically constant rate of piston movement. Control by this valve
allows extensometer readings to be taken.
5. Load Indicator System :
This system consists of a large dial and a pointer. A dummy pointer is provided to register
the maximum load reached during the test. Different measuring ranges can be selected by
operating the range selection knob. An overload trip switch is incorporated which automatically
cuts out the pump motor when the load range in use is exceeded.
6. Pendulum Dynamometer :
This unit permits selection of favourable hydraulic ratios producing relatively small
frictional forces. Pressurised oil in the loading cylinder pushes up the measuring piston
proportionately and actuates the special dynamometer system. The piston is constantly rotated to
eliminate friction.The dynamometer system is also provided with an integral damper and ensures

high reliability of operation.The load transmitted to the dynamometer is transferred through a

pendulum to the load indicator.
7. Autographic Continuous Roll Load-Elongation Recorder :
This unit is of the pen and drum type and is supplied as standard. The horizontal motion of
the pen produces the load ordinate of the diagram and the drum rotation produces the extension
ordinates, in the ratio of either 1:5 or 1:10. A continuous roll of graph paper is stored inside the
drum and is easily replaced.
Safety Devices :
The rams have a fixed travel distance of and it is not safe to push the ram beyond this
travel.
Accordingly, When the ram has reached its maximum height, oil under the
ram will flow along a tube and reach back to the tank with some valve arrangement.
Oil is diverted by the pump into the inlet control box at a steady rate. When the inlet valve
is closed, the oil pressure will start increasing in the inlet chamber. Before this pressure reaches
dangerously high value, a bye-pass valve is arranged in the chamber through which oil flows
back to oil tank.
As the measurement of load depends upon the oil pressure transmitted to the pendulum,
any friction existing between the cylinder and the piston which will cause errors in the test and
this error is reduced to its maximum by putting the dynamometer cylinder into small rotation.
This lubricates the unit and reduces the friction.
A. ELECTRONIC UNIVERSAL TESTING MACHINE
Electronic universal Testing Machine is designed for testing metals and other materials
under tension, compression, bending, transverse and shear loads. Hardness test on metals can
also be conducted.
A Schematic view of Electronic Universal Testing Machine
Main Features :
The Main features of an Electronic Universal Testing Machine are same as that for an
ordinary
Universal Testing Machine with some extra features.
* Printer supplied as option to enable study of the behavior of the material.
* Simplicity in reading because of digital readouts.
* Optional serial port to transfer data to computer for analysis / storage evaluation etc.
* The microprocessor based electronic control panel features the following
- Print port interface
- Storage of important parameters such as peak load, displacement at peak load etc.
- Serial port for communication with PC.

- Preload selection to take care of initial slippage.

* Window based software package on PC to enable the user to effectively evaluate
different
parameters.
* Available with various maximum capacity ranges viz., 100 kN, 200 kN, 400 kN, 600 kN,
1000 kN, 2000 kN and 3000 kN.
B. COMPUTERISED UNIVERSAL TESTING MACHINES
They are microprocessor based electro mechanical machines with servo drive designed for
testing and studying mechanical behaviour of various materials like metals, polymers, elastomers
etc. These
machines offer excellent stand along performance for standard tests and
great flexibility for complex

analysis.

These machines confirm to BIS, BS & ASTM

standards.

A Schematic view of Computerised Universal Testing Machine

Main Features :
* Servo drive with ball lead screw gives an advanced drive system with 1 to 1000
standard
speed
range
* Speed selection through keyboard entry with auto or variable speed selection.
* Facility for mounting different load cells and clamping devices to suit different tests and
materials
such as thin wires, metalsheets, fiberglass, leathers, springs, cardboards etc.
* Safety interlock for overload and limit switch sensing to ensure protection during test.
* Universal applications in R & D, education, quality control and production for tests like
tensile,
compression, bending etc.
* The microprocessor based electronic control panel incorporates the following features :
Input and output data storage. Maintains data and results during power off.
Data analysis, statistics with point tracing, superimposing graphs to compare
with
standard, zooming graph etc
Printer port for printer interface with

- Graph and result printout

- Test certificate printout
- Batch certificate printout
- Simple statistics printout
The software packages available are :
1) Basic evaluation 2) Exhaustive evaluation 3) Rubber textile 4) Compression, Shear &
Bending
5) Torsion test 6) Spring testing

.
2. STUDY OF TORSION TESTING MACHINE
Aim :
To study the various parts and working of Torsion Testing Machine.
General :
The torsion testing machine is designed for conducting torsion and twist on various metal
wires, tubes, sheet materials. The accuracy of torque indication is 1% of the true torque. The
torsion testing machine is available with various maximum torque capacity viz., 60 N-m, 100 Nm, 200 N-m, 500 N-m, 1000 N-m, 2000 N-m, 3000 N-m and 6000 N-m.
Principle of Operation :
Operation of the machine is by hydraulic transmission of torque from the test specimen to a
separately housed torque indicator.
Torque is applied to the specimen by a geared motor through gear box. Main cylinder
pressure is transmitted to the cylinder of the pendulum dynamometer system, housed in the
control panel. The load transmitted to the cylinder of the dynamometer is transferred through a
lever system to a pendulum.
Displacement of the pendulum actuates the rack and pinion mechanism which operates the
torque indicator pointer and the autographic recorder. The deflection of the pendulum represents
the absolute torque applied on the test specimen. Return movement of the pendulum is
effectively damped to absorb energy in the event of sudden breakage of a specimen.
A Schematic view of Torsion Testing Machine
It consists of the following units
1. Auto Torque Selector
2. Geared Motor / Gear Box
3. Torque Indicator
4. Pendulum Dynamometer
5. Autographic Recorder
1. Auto Torque Selector :
Torque ranges can be adjusted by auto torque selector. Selection of torque limit depends
on the various materials viz., metal wires, tubes, sheet metals. The various torque ranges
available are 20 N-m, 30 N-m, 50 N-m, 60 N-m etc upto 6000 N-m.

2. Geared Motor / Gear Box

Torque can be applied to the specimen by geared motor through gear box. Initially, the
torque is applied by hand upto 20 angle of twist. After this, the machine may be operated
electrically so that torque is applied by geared motor through gear box until the specimen breaks.
Depending on various torque ranges, the motor, 3 phase, 400-440 V and 50 Hz with various
horse power viz., 0.5 HP, 1.0 HP, 1.5 HP and 3.0 HP may be used.
3. Torque Indicator :
This system consists of a large dial and a pointer. Different measuring ranges can be
selected by operating the auto torque selector knob.
4. Pendulum Dynamometer :
The torque measurement is by pendulum dynamometer system. This unit permits selection
of favourable torque ratios. Pressurised oil in the loading cylinder pushes up the measuring
piston proportionately and actuates the special dynamometer system. The dynamometer system
is also provided with an integral damper and ensures high reliability of operation. The load
(torque) transmitted to the dynamometer is transferred through a pendulum to the load (torque)
indicator.
5. Autographic Recorder :
This unit is of the pen and drum type and is supplied as standard.

The horizontal

movement of the pen produces the angle of twist in degrees and the drum rotation produces the
torque ordinates. Thus the autographic recorder gives the relation between torque and angle of
twist.

3. STUDY OF HARDNESS TESTER

Aim :
To study the various parts and working of a hardness tester.
General :
Hardness may be defined as resistance to penetration or resistance to abrasion. For a
number of engineering materials which are subjected to friction such as steel, cast iron,
aluminium, brass etc, it is necessary to find out their resistance to wear and tear (Hardness).
Hardness is determined by measuring the permanent depth of indentation. It is achieved by
using a fixed force (load) and a given indentor. The smaller the indentation, the harder the
material. Indentation hardness is obtained by measuring the depth or the area of the indentation
using different test methods.
Methods of Testing :
1. Brinell hardness test
2. Rockwell hardness test and
3. Vickers hardness test
The Brinell and Rockwell hardness test are most commonly adopted tests in laboratories.
A. STUDY OF BRINELL HARDNESS TESTING MACHINE
The Brinell hardness testing machine is designed to measure hardness of castings, forgings,
other metals and alloys of all kinds, hard or soft, flat, round or irregular in shape.
Principle of Operation :
The Brinell hardness test is carried out by forcing a hardened steel ball or carbide ball of
diameter D under a load P for 15 to 30 seconds into a test specimen and measuring the mean
diameter d of the indentation left on the surface after the removal of the load, twice and
averaged. A formula or chart is then used to convert the averaged measurements to a Brinell
hardness number (B.H.N). It is calculated using the following formula.
B.H.N =
Where

P = load applied

D = diameter of the indentor

d = diameter of the impression.
Ordinary Type

Electronic Type

Brinell Hardness Tester

The following are the units of a Brinell hardners testor :
1. Testing table
2. Indentors
3. Loading device and
4. Brinell Microscope
1. Testing table :
The testing table is vertically adjustable so that it can be raised or lowered and it is of
diameter
200 mm. For round jobs, a testing table of 70 mm diameter with V groove is
available.
2. Indentors :
Steel ball indentors of 1 mm, 2 mm, 2.5 mm, 5 mm and 10 mm diameter are used.
Normally for hard materials, a ball of 10 mm diameter shall be used. For soft materials 5 mm,
2.5 mm, 2 mm and 1 mm diameter balls are used depending upon the softness of the surface.
The British Standard Institutions has recommended the folllowing four different P/D2 ratio for
different materials.
1. Steel and cast iron

: 30

2. Copper and Aluminium alloys

3. Copper and Aluminium

4. Lead, Tin and alloys

10

The indentors are kept safe in ball holders when not in use.
3. Loading device :
The machine is designed with a hydraulic pack and control circuit for effortless loading
and unloading operation. The loading device can be either manually operated or motorised for
automatic operation. The loading capacity of the machine ranges from 500 kgf to 3000 kgf in
stages of 250 kgf. The machine applies a load of 500 kgs for soft metals such as Copper, Brass
and thin stock. A 1500 kg load is used for Aluminium castings, and a 3000 kg load is used for
materials such as Iron and Steel.

4. Brinell Microscope :
Several models of Brinell microscopes are available ranging from a low cost flashlight
style unit to advanced LED illuminated microscopes. The diameter of the indentation correct to
0.1 mm should be
measured using the Brinell microscope which is a separate
attachment. In some advanced machines, an optical device with 14 magnification provided in
front to project diameter of ball impression on glass screen with a micrometer measuring system
with 0.01 mm accuracy. The indentor swivels and projects diameter of ball impression
immediately after unloading operation which avoids additional time for measurement of ball
impression. This gives real Brinell number on production testing.
B. STUDY OF ROCKWELL HARDNESS TESTING MACHINE
In 1919, Stanely P. Rockwell introduced this direct reading hardness number of the
material. This is the most commonly used hardness testing operation, since it is generally easier
to perform and more
accurate than other types of hardness testing. Rockwell can be
used on all metals, except in conditions where the test metal structure or surface conditions
would introduce too much variation.
Principle of Operation
The Rockwell test consists of forcing an indentor (Diamond or Ball) into the surface of a
test piece in two steps i.e., first with preliminary test force and thereafter with additional test
force and then measuring depth of indentation after removal of additional test force (remaining
preliminary test force active) for measurement of hardness value. The hardness number is shown
directly on the indicator.
Ordinary Type
Rockwell Hardness Tester

Electronic Type

The following are the units of a Rockwell hardness testing machine.

1. Testing table
2. Indentors
3. Standard scales
4. Loading device and
5. Dial gauge
1. Testing Table :
The testing table is vertically adjustable so that it can be raised or lowered and it is of
diameter 50 mm. For round jobs, a testing table of 6-45 mm diameter with V groove is
available.

2. Indentors :
A diamond indentor of 120 cone angle and steel ball indentors of diameter 1/16(1.5875
mm),
1/18(3.175 mm), 1/4(6.35 mm) and 1/2(12.7 mm) are available.
3. Standard Scales :
The standard scales B and C with a load of 1000 N (100 kg) and 1500 N (150 kg) are
used. For soft materials like copper alloys, soft steel, and aluminium alloys, a 1/16(1.5875 mm)
diameter steel ball indentor is used with a 100 kg load and the hardness is read on the B scale.
For harder materials like hard cast iron and many steel alloys, a 120 diamond cone indentor is
used with a load upto 150 kg and the hardness is read on the C scale.
4. Loading Device :
The loading device can be either manually operated or motorised for automatic operation.
The loading capacity of the machine ranges from 60 kgf, 100 kg, 150 kgf and 250 kgf. A minor
load of 100 N (10 kg) is applied by forcing the specimen into the penetrator using the elevator
screw. The use of this minor load results in the establishment of a reference datum within the
specimen itself.
5. Dial Gauge :
The hardness number is shown directly on the dial gauge indicator. All machines are
provided with automatic zero setting dial gauge or digital readout. Hence zero setting at every
test is avoided. In the digital dial gauge, large size scale display of easy reading with 0.1
Rockwell resolution is provided.

4. STUDY OF COMPRESSION TESTING MACHINE

Aim :
To study the various parts and working of the compression testing machine.
General :
The compression testing machine is designed to test metals and other materials under
compression, bending, transverse and shear loads. Hardness test on metals can also be
conducted. The compression testing machine is available in different capacities viz., 500 kN,
1000
kN,
2000
kN,
3000
kN,
and
5000 kN.
Principle of operation :
Operation of the machine is by hydraulic transmission of load from the test specimen to
separately housed load indicator. The hydraulic system is ideal since it replaces transmission of
load through levers and knife edges, which are prone to wear and damage due to shock on
rupture of test pieces.
Load is applied by a hydrostatically lubricated ram. Main cylinder pressure is transmitted
to the
cylinder of the pendulum dynamometer housed in the control panel. The
cylinder of the dynamometer is also of self-lubricating design. The piston of the dynamometer is
constantly rotated to eliminate friction. The load transmitted to the cylinder of the dynamometer
is transferred through a lever system to a pendulum.
Displacement of the pendulum
actuates the rack and pinion mechanism which operates the load indicator pointer and the
autographic recorder. The deflection of the pendulum represents the absolute load applied on the
test specimen.
Return movement of the pendulum is effectively damped to absorb energy in the event of
sudden breakage of specimen.
It consists of the following units :
1. Straining unit
2. Contol panel
i. Power Pack
ii. Hydraulic Controls

iii. Load indicator System

iv. Pendulum Dynamometer
v. Autographic Continuous Roll Load-Elongation Recorder.

A Schematic view of Compression Testing Machine

1. Straining unit :
It consists of a hydraulic cylinder and a table coupled with the ram of hydraulic cylinder,
mounted on to a robust base. The cylinder and the ram are individually lapped to eliminate
friction. The cross-head is connected to two screwed columns and is driven by a motor, for a
rapid adjustment of test height. AN elongation scale with minimum graduation of 1.0 mm, is
provided to measure the deformation of the
specimen. Compression, transverse, bending,
shear and hardness tests are conducted between the cross head and the table.
2. Control panel :
The Control Panel consists of a power pack complete with drive motor and an oil tank,
control valves, a pendulum dynamometer, a load indicator system and an autographic recorder.
i. Power Pack :
The power pack generates a maximum pressure of 200 kgf/cm2. The hudraulic pump
provides continuously non-pulsating oil flow. Hence the load application is very smooth.
ii. Hydraulic Controls :
Hand operated wheels are used to control the flow to and from the hydraulic cylinder. The
regulation of the oil is infinitely variable. Incorporated in the hydraulic system is a regulation
valve, which maintains a practically constant rate of table movement.
iii. Load indicator System :
This system consists of a large dial and a pointer. A dummy pointer is provided to register
the maximum load reached during the test. Different measuring ranges can be selected by
operating the range selection knob.
An overload trip switch is incorporated which
automatically, cuts out the pump motor when the load range in use is exceeded.
iv. Pendulum Dynamometer :
This unit permits selection of favourable hydraulic ratios producing relatively small
frictional forces. Pressurised oil in the loading cylinder pushes up the measuring piston
proportionately and actuates the special dynamometer system. The piston is constantly rotated to
eliminate friction. The Dynamometer system is also provided with an integral damper and

ensures high reliability of operation. The load

transferred through a pendulum to the load indicator.

transmitted to dynamometer is

v. Autographic Continuous Roll Load - Elongation Recorder :

This unit is of the pen and drum type and is supplied as standard. The horizontal motion of
the pen produces the load ordinate of the diagram and the drum rotation produces the extension
ordinate, in the ratio of either 1:5 or 1:10. A continuous roll of graph paper is stored inside the
drum and is easily replaced.

1. TENSION TEST ON MILD STEEL BARS

Aim :
To conduct tension test on the given steel specimen for determining the
1. Stress at yield point
2. Ultimate stress
3. Nominal breaking stress
4. Actual breaking stress
5. Percentage elongation
6. Percentage reduction in area
7. Youngs modulus
Apparatus :
1. Universal Testing Machine
2. Vernier calipers
3. Scale
4. Dot punch
5. Hammer
Procedure :
A.For mild steel specimen :
Calculate the probable ultimate load for the given specimen assuming the probable
ultimate stress of 420 N/mm2. Adjust the U.T.M. for that selected range.
Take a convenient length (Approximately 300 to 400 mm) of the specimen and mark
the cen tre. From the centre, mark 100 mm on either side using dot punch and
hammer.
Measure the diameter of the given mild steel specimen at three different places with
the help of vernier calipers and determine the average diameter of the specimen.
Mount the specimen in the grip of the movable and fixed cross head and fix the
extensometer.
Adjust the load stabilizer, start the machine and open the inlet valve slightly. When
the load pointer just kicks it, indicates that the rod is held tight between the grips.
Then adjust the pointer to read zero.
Apply the load at the steady uniform rate and note the extension within elastic limit.
Remove the extensometer.

 At a particular stage there will be a pause in the increase of load. The load at this
point is noted down as Yield point load.
Apply the load continuously. When the load reaches the maximum value, both the
actual pointer and the dummy pointer which has been accompanying it will remain
stationary.Record the maximum load reached as Ultimate load.
After sometime the actual pointer returns slowly. At this stage, a neck is formed in
the specimen and the specimen breaks. Note the position of actual pointer during
breaking.Record the maximum load as Breaking load.
After breaking, remove the specimen from the grips and measure the final gauge
length and the final diameter. For mild steel, a typical cup and cone fracture is
observed.
Observations :
Diameter of rod Trial I

Trial II

Trial III

Average diameter of rod (D)

Original length (gauge length) of rod (L1)

Yield point load (Py)

Ultimate load (Pu)

Breaking load (Pb)

Diameter of the rod at neck (L2)

Least count of extensometer

Graph :
Draw the graph between Stress (Y-axis) and Strain (X-axis). From the graph, for a chosen
stress, read the corresponding strain.
Calculation :
Original area of cross section (A) =

Area of cross section at neck (a) =

Stress at yield point

Ultimate stress

Nominal breaking stress

Actual breaking stress

Percentage elongation

Percentage reduction in area

100 =

Youngs modulus

Result :
1. Stress at yield point

2. Ultimate Stress

3. Nominal breaking stress

4. Actual breaking stress

5. Percentage elongation

6. Percentage reduction in area =

7. Youngs modulus

Procedure :
B.For Torsteel specimen :
1. Select the required load range in the U.T.M.
2. Take a convenient length of the specimen.
3. Repeat the procedure, given for mild steel specimen
Observations :
Diameter of rod - Trial I

Trial II

Trial III

Average diameter of rod (D)

Original length (gauge length) of rod (L1)

Ultimate Load (Pu)

Breaking Load (Pb)

Final length of rod (L2)

Least count of extensometer

Graph :
Draw the graph between Stress (Y-axis) and Strain (X-axis). From the graph, for a chosen
stress and read the corresponding strain.
Calculation :
Area of cross section (A)
Ultimate Stress
Percentage elongation
Youngs modulus

=
=
=
=

Result :
1. Ultimate stress

2. Breaking stress

3. Percentage elongation

4. Youngs modulus

=
=
=
=

2. DEFLECTION TEST ON STEEL BEAM

Aim :
To conduct deflection test on the given mild steel section (L-Section / I-Section / Hollow
circular section) for determining the
1. Youngs modulus
2. Bending Stress
Apparatus :
1. U.T.M. with deflection bench arrangement
2. Deflectometer
3. Calipers
4. Scale
Test Specimen
1. Mild Steel L - Section
2. Mild Steel I - Section
3. Mild steel hollow circular section
Procedure :
1. Adjust the span of deflection bench arrangement as required.
2. Measure the dimensions of the given specimen with the help of the calipers.
3. Mark the required span on the specimen and place the specimen centrally on the
supports with equal overhangs.
4. Place the deflectometer under the specimen at the centre of span.
5. Select the lowest load range for the test.
6. Apply the central load gradually upto a maximum of 2000 N (200 kg). Record the
deflectometer readings while loading and unloading at every 200 N (20 kg) loading intervals.
7. Draw the graph for load W (in N) vs deflection (in mm) taking deflection on Xaxis and load on Y-axis.
8. If the graph is not passing through origin, draw a line parallel to the graph and
passing through the origin.
Observations :
Cross section of the specimen

Least count of the deflectometer :

Graph :
Draw the graph between load (Y-axis) and deflection (X-axis). From the graph, for a
chosen load, read the corresponding deflection.
Calculation :
A. From a central load, W, in a simply supported beam of span l,
Deflection at centre,

Moment of inertia, I

=
E

From the bending equation,

Bending stress,

=
,

B. For a simply supported beam of span l with a central load W and if deflection is measured
at
a distance X from one support.

Hence,
Hence bending equation,

(3l2X4X3)

(3l2X-4X3)

=
=

Result :
1. The youngs modulus E of the given materials is .............. N / mm2
2. The bending stress at the applied maximum load is ............ N / mm2

3. DEFLECTION TEST ON WOODEN BEAM

Aim :
To determine the Youngs modulus and bending stress for the given wooden beam by
conducting deflection test.
Apparatus :
1. Two knife edge supports
2. Deflectometer
3. Calipers
4. Scale
5. Load ranger
6. Set of weights
Procedure :
1. Adjust the knife edge supports for the required span.
2. Place the test beam over the centre of supports.
3. Place the deflectometer under the beam where the deflection is to be measured.
4. Suspend the hanger at the point where the beam is to be noted.
5. Note the initial reading of the deflectometer.
6. Add the loads to the hanger at the rate of 5 N (500 g)
7. Note the corresponding deflectometer reading for each increasing load.
8. Observe five sets of reading.
9. Remove the loads at the rate of 5 N (500 g)
10. Note the corresponding deflectometer reading for each decreasing load.
11. Draw the graph for load W (in N) vs deflection (in mm) taking deflection on X-axis
and load on Y-axis.
12. If the graph is not passing through origin draw a line parallel to the graph and passing
through the origin.
Observations :
Span of the beam

Size of the beam

Least Count of the deflectometer =

Graph :
Draw the graph between load (Y-axis) and deflection (X-axis). From the graph, for a
chosen load, read the corresponding deflection.
Calculation :
A. For a simply supported beam of span l with a central load W and deflection is measured at
mid span.
Deflection at centre,

Moment of Inertia, I

=
E

From the bending equation,

Where

=
E

Youngs modulus of the material

Moment of inertia of the cross-section

Bending moment

Bending stress

Distance of the fibre from the N.A

B. For a simply supported beam of span l with a central load W and if deflection is
measured
at a distance X from one support.
=

(3l2X 4X3)

Hence,
E = (3l2 X 4X3)
Hence bending equation,

=
=

Result :
Youngs modulus of beam material is

...................... N / mm2

Bending stress at the applied maximum load is

...................... N / mm2

5. INITIAL AND FINAL SETTING TIME OF CEMENT

Aim :
To determine the initial and final setting time of cement.
General Introduction :
When water is mixed with cement to form a paste, reaction starts. The action of changing
of the cement paste from fluid state is called setting. Setting of cement depends on the quantity
of gypsum contained in it. In practice, such solidifying action or loss of plasticity is to be
delayed because some time is needed for mixing, transporting and placing of concrete into final
position before the mix loses its plasticity due to setting action.
For the initial setting time test, a needle of 1 mm square section is to be fitted to the
moving rod, while for the final setting time test, the needle with annular attachment is to be used.
Apparatus :
1. Vicat apparatus with a needle of 1 mm square section and a needle provided with an
annular
attachment and a vicat mould
2. Trowel
3. Nonporous plate
4. Measuring jar
5. Stop watch
Procedure :
A. Initial Setting Time Test :
1. The mould and the nonporous plate are washed, cleaned and dried.
2. 400 g. of the given sample of cement is kept on the nonporous plate.
3. The volume of water equal to 0.85 times the percentage of water required for standard
consistency is added very carefully to the dry cement and mixed throughly to form a
neat cement paste.The mixing is completed within 3 to 5 minutes from the moment of adding
water. At the instant of adding water to the cement, the time taken is noted by using a stop
watch.
4. The Vicat mould is placed on the nonporous plate and is filled with the prepared
cement paste and the surface of the paste is made smooth in level with the mould by using a
trowel.
5. By shaking the mould slightly, air if any, is expelled from the sample.
6. The nonporous plate and the mould are placed under the needle.

7. The needle is gently lowered to touch the surface of the plate and then the indicator is
adjusted to show zero reading.
8. The needle is released quickly allowing it to penetrate into the paste.
9. When the needle comes to rest, the reading on the index scale is noted.
10. The moving rod is raised clear off the cement paste and is wiped clean. The procedure
of releasing the needle is repeated at every 30 seconds until the reading on the index scale shows
5 0.5 mm from the bottom of the mould.
11. Then the time is noted down.
The time that elapsed between the moment when water is first added to the cement and
the moment at which the needle of 1 mm square section failed to pierce the test block to a depth
to 5 0.5 mm from the bottom of the mould is the intial setting time for the cement under the test.
B. Final Setting Time Test :
1. The needle used in the former test is replaced by the needle provided with an annular
attachment.
2. The steps (8) to (10) described above are repeated.
3. Then releasing the needle is continued at every 2 minutes till the needle makes an
impression on the test block, while the attachment fails to do so.
4. Then the time is noted down.The time that elapsed between the moment when water is
first added to the cement and the moment at which the needle only makes an impression on the
test block, while the attachment fails to do so is the final setting time for the cement under the
test.

Result :
Initial setting time of cement is ........... minutes.
Final setting time of cement is ............ hours.
Inference :
The minimum initial setting time specified by I.S.I. for ordinary cement and rapid
hardening cement is to be not less than 30 minutes and 60 minutes for low heat cement.
As per I.S. 4031, the maximum time for final setting for all types of cement is to be not
more than 10 hours.

Comment :

6. TORSION TEST ON M.S. BAR

Aim :
To conduct a torsion test on mild steel specimen for finding the following :
1. Shear stress under a twist of one degree
2. Modulus of rigidity
3. Strain energy under a twist of one degree
4. Ultimate torsional stress
Apparatus :
1. Torsion testing machine
2. Vernier calipers
3. Scale
Procedure :
1. Adjust the steel yard to horizontal with the poise at zero.
2. Introduce the specimen between the chucks and grip the specimen tightly.
3. Apply the torque gradually by rotating the loading wheel.
4. Note down the torque indicated by the vernier in the steel yard for every 0.1 angle
of twistup to a maximum of 1 read in the protractor.
5. Operate the motor to increase the rate of torque till the test piece breaks. Now, note
down the maximum torque applied to the specimen.
Observations :
Dia. of specimen (d) =
Length of specimen (e)

Graph :
Draw the graph between torque (Y-axis) and angle of twist in degrees (X-axis). From the
graph, for a chosen torque, read the corresponding angle of twist.
Calculation :
Basic formula : =

Where, T = Torque applied in Nm

J = Polar moment of Inertia =

fs = Shear stress
R = Radius of the specimen
N = Modulus of rigidity
= Angle of twist due to the applied torque
l = Gauge length of the specimen
Shear stress under a twist of 1 (fs) =

Modulus of rigidity (N)

Strain energy for a twist of 1

= V

(Where V = Volume of specimen = )

Ultimate torsional stress,

Result :
1. Shear stress under a twist of 1

2. Modulus of rigidity

3. Strain energy under a twist of 1 =

4. Ultimate torsional stress

PART - B
1. DOUBLE SHEAR TEST ON M.S BAR
Aim :
To determine the ultimate shear stress of mild steel rod by conducting a double shear test.
Apparatus :
1. Compression testing machine
2. Double shear apparatus
3. Calipers
Procedure :
1. Measure the diameter of steel rod.
2. Fix the steel rod in the double shear assembly with proper side grips.
3. Apply the load to specimen.
4. Note down the ultimate load at the time of failure of steel rod.
5. Repeat the procedure for a number of specimen.
Observations :
Diameter of the steel rod

Cross sectional area of the specimen

Calculation :
Ultimate shear stress

Result :
Ultimate shear stress of the steel rod

2. (A) ROCK WELL HARDNESS TEST

Aim :
To measure the hardness of different materials like 1) Hard Steel 2) Mild Steel 3)
Aluminium and
4) Brass.
Apparatus :
1. Rock well hardness testing machine.
2. 00 - Emery paper
Procedure :
1. Remove all mill scales from the surface of specimen by rubbing it with 00-Emery
paper.
2. Based on the type of materials, select the proportional load and the indenting tool. For
very hard materials - measure Rock Well C scale, 1500 N proportional load and diamond
penetrator. For medium hard and soft materials, measure in Rockwell B scale, 1000 N
proportional load and 1.58 mm dia. ball penetrator.
3. Insert indentor and fasten with a screw.
4. Put the required weight on the pan.

5. Plate the specimen on the anvil and turn the wheel to raise the elevating screw till the
small pointer on the dial reaches the set position. Now the specimen is subjected to the
preliminary load of 100 N.
6. Push forward the loading handle to transmit the major load to the specimen.
7. When the penetration is complete (Give 5 to 6 seconds for hand material and 6 to 8
seconds for soft material) release the major load by pushing backward the loading handle. Keep
the initial 100 N load still on the specimen.
8. Then directly read the Rockwell C or Rockwell B hardness number on the dial and
record it.
9. Then release the minor load of 100 N by rotating the hand wheel and lowering the
screw.
10. Repeat the experiments to obtain atleast four different sets of observations for the same
material.

Observations :

Result :
1. Rockwell hardness no. for hard steel

2. Rockwell hardness no. for mild steel

3. Rockwell hardness no.for aluminium

4. Rockwell hardness no. for brass

2. (B) BRINELL HARDNESS TEST

Aim :
To measure the Brinell Hardness number for the given specimen.
Apparatus :
1. Brinell hardness testing machine
2. Microscope to measure the dia. of ball impression
3. Stop watch
4. 00 - Emery paper
Procedure :
1. Polish the surface of the specimen with 00 - Emery paper.
2. Place the specimen on the work table and raise the table by turning the elevating screw
till the short dial points to the red mark on the dial indicator.
3. Adjust the dial for the required weight, that is, if the penetrator dia. is 25 mm and
ratio is 30, then the load to be adjusted is 187 kg. (1875 N). If the dia. of penetrator is 10 mm,
then the load is 3000 kg. (30000 N).

4. Apply the load by operating the lever arm.

5. Wait for 30 seconds for soft materials and 15 seconds for hard materials so as to make
the load reach the specimen fully. Wait till the pointer stops moving.
6. Remove the specimen and measure the diameter of the indentation correct to 0.1 mm
with the Brinell microscope. To do this, keep the block vertical line of the microscope tangential
to the indentation and rotate the hand of microscope till it comes tangential to the opposite side
of the indentation.
7. Using the following formula, calculate the Brinell hardness number (B.H.N).
B.H.N

Where P is the load adjusted in the machine in N

D is the dia. of the indentor and
d is the dia. of the impression

Observation and calculation :

Result :
1. Brinell hardness number for mild steel

2. Brinell hardness number for cast iron =

3. Brinell hardness number for brass

3. COMPRESSION TEST ON WOODEN CUBE

Aim :
To determine the compressive strength while loading the specimen with grains parallel to
and
perpendicular to the applied load.
Apparatus :
1. Universal testing machine or compression testing machine or Amslers wood testing
machine
2. Scale
Procedure :
A. Loading parallel to grain :
1. Select the required load range.
2. Place the specimen centrally between the bearing plates keeping the grains parallel to
load.
3. Start the machine and adjust the load pointer to zero.
4. Apply the load continuously on the specimen by making the movable head of the
testing machine to travel at a constant speed.
5. Record the load when the specimen gets fractured. At this point the pointer returns
back to zero.

B. Loading perpendicular to grain :

1. Place the specimen centrally between bearing plates with the grains perpendicular to
load
2. Repeat the procedure given in A and note the maximum crushing strength.
Observation :

Calculation :
Compressive stress at maximum load
(Parallel to grain)
Compressive stress at maximum load
(Perpendicular to grain)

Working stress or permissible stress

Working stress (Parallel to grain)

Working Stress (Perpendicular to grain)

Result :
Maximum compressive strength
a. When loaded parallel to grain

b. When loaded perpendicular to grain =

4. IMPACT TEST ON M.S. SPECIMEN
Aim :
To determine the Impact resistance of materials using Charpy type and Izod type
specimens in impact testing machine.
Apparatus :
1. Impact testing machine - Charpy type and Izod type
2. Vernier calipers.
3. Scale.
Procedure - A. Charpy Test
1. Measure the dimensions of the specimen.
2. Rise the pendulum and keep it in position.
3. Adjust the pointer to coincide with initial reading.
4. Place the specimen centrally over the supports such that the notch is opposite to
striking end.

5. Release the pendulum by pulling the string. The striking edge strikes against the
specimen and ruptures it. The specimen absorbs a part of the energy due to the fall of the
pendulum.
Observation :

Calculation :
Specific Impact Power =

Result :
Specific Impact Power of the given material

Procedure - B. Izod Test

Repeat the test by fixing the specimen as a cantilever specimen.

Observation :

Calculation :
Specific Impact Power

Result :
Specific Impact Power of the given material

5. FINENESS TEST ON CEMENT

Aim :
To determine the fineness of cement by sieving.
Apparatus :
1. Balance
2. I.S. Test sieve No. 9
3. Trowel
4. Bristle brush
Procedure :
1. Air set lumps if any in the cement sample are removed with fingers.
2. About 100 g of cement is weighed (W1) accurately.
3. It is sieved in I.S. Sieve No. 9 continuously for 15 minutes in a sieve shaker. After
every five minutes of sieving, the underside of the sieve is lightly brushed with a bristle brush.
4. The residue left after 15 minutes of sieving is weighed (W2).

5. The experiment is repeated thrice for the same sample of cement and the average
percentage weight of residue is calculated.
Observation and calculation :
Types of
cement

Cement
sample

Wt. of.
sample
W1(g)

100

100

100

100

100

100

Wt. of Percentage
Average
residue Wt.of residue Percentage of
W2(g) 100 residue

Remark

Result :
Average fineness of cement ......... %
Inference :
For ordinary portland cement, the fineness by weight should not be more than 10%

6. COMPRESSION TEST ON BRICKS

Aim :
To determine the crushing strength of bricks by conducting compression test.
Apparatus :
1. Steel rule
2. Compression testing machine
Procedure :
1. By grinding unevenness in the bed faces is removed to provide two smooth parallel
faces.
2. They are immersed in water at room temperature for 24 hours.
3. The specimens are removed and the surplus moisture is dried out at room temperature.
4. The frog and all voids in the bed faces are filled flush with cement mortar, 1 cement : 1
clean coarse sand of grade 3 mm and below.
5. They are stored under damp jute bags for 24 hours followed by immersion in clear
water for 3 days.

6. They are moved and wiped out for any traces of moisture.
7. The specimen is placed with flat faces horizontal and mortar filled faces facing
upwards, between two plywood sheets of 3 ply each of 3mm thick and carefully centered
between theplates of the compression testing machine.
8. Load is applied axially at the uniform rate of 14 N / mm2 (140 kg/cm2) per minute till
cracks are notified first. This is the load at initial crack.
9. The loading is continued till the specimen failed or crushed completely. The load at
failure is the maximum load at which the specimen failed.
10. The above procedure is repeated on a number of specimens and the observations are
tabulated and the average compressive strength is computed.

Observations :
Mark of
Specimen identifiNo. cation

1
2
3
4
5

Average Value :

Specimen details
Dimensions of
Height
Cross-section
cm
mm
cm mm

First crack
Load
kg N

Stress
kg/ N /
cm2 mm2

Crushing
Load

Stress

kg N kg/ N/
cm2 mm2

Model calculation :
The compressive strength is given by,
Compressive strength

=
= .......................... = ................... kg/cm2

Result :
= ................. kg/cm2

Compressive strength of the given brick

= ................. N/mm2
Inference :
Better compaction and high temperature burning at the time of manufacture tend to
produce bricks with better compressive strength. Country bricks have low crushing strength.
As per National Building Code 1970, well burnt bricks having a crushing strength not less
than 3.5 N/mm2 (35 kg/cm2) shall be used.

7. WATER ABSORPTION TEST ON BRICKS

Aim :
To determine the water absorption of bricks by conducting water absorption test on bricks.

Apparatus :
1. Steel rule
2. Sensitive balance
3. Ventilated oven
Procedure :
I. Cold Water test :
A. Preconditioning :
1. The specimen is dried in a ventilated oven at a temperature of 105C to 115C till it
attained substantially constant mass.
2. The specimen is cooled to room temperature and its mass (W1) is determined.
B. Procedure :
1. The completely dried specimen is immersed in clean water at a temperature of (272)
C for 24 hours.
2. The specimen is removed and wiped out of any traces of water with a damp cloth and
weighed(W2) within three minutes.
3. The above procedure is repeated on fresh specimens and all the observations are
tabulated and the average percentage water absorption is worked out.

Observations :
Average value =

Model calculation :
Percentage water absorption

= 100

=
=

Result :
Water absorption of the given sample of bricks
%
II. Boiling water Test :
A. Preconditioning :
Same as for cold water test.

Note : For sample obtained after 24 hours immersion test no preconditioning is required.
B. Procedure :
1. The specimen is immediately immersed in water and is placed in such a way that water
can freely circulate on all sides of the specimen.
2. The water is occasionally stirred to ensure complete expulsion of air.
3. The water is heated to boiling in one hour and continuously boiled for 5 hours.
4. Then it is cooled to (27 5) C by natural loss of heat for 16 to 19 hours.
5. Any surplus moisture is removed by rubbing with damp cloth and weighed (W 3)
within 3 minutes.
6. The above procedure is followed on other specimens also and the average percentage
water absorption is determined.
Observations :
Average =
Calculation :
Water absorption percentage after 5 hours of immersion in boiling water
= 100 =
=

Result :
Water absorption of the given sample of brick is =

8. DETERMINATION OF FLEXURAL STRENGTH OF TILES

Aim :
To conduct deflection test on the given tile specimen for determining the flexural strength.

Apparatus :
1. U.T.M with transverse test arrangement
2. Scale
Test Specimen :
1. Tiles - 6 nos.
Procedure :
1. Take six tile specimens for testing.
2. Measure the dimensions of the given specimen with the help of scale.
3. Select three tiles in dry condition, that is after drying in an oven at 100 c to 110 c till
constant weight is attained.
4. Select the other three tiles in wet condition, that is, after soaking in water at 24 c to
30 c for24 hours.
5. Adjust the span of the test arrangement so that the span between the supports shall be
equal to three-fourths the dimension of the tile.
6. Place the specimen horizontally on the supports with wearing surface upwards and its
sides parallel to the supports.
7. Apply the load centrally with the direction of the load perpendicular to the span at a
uniform rate of 45 to 55 kg/min.
8. Record the load at breaking for all specimens.
9. The flexural strength of the tile shall be obtained by dividing the breaking load by the
width of the tile and the average of the six values calculated.
Flexural strength

Observations :
Length of the specimen = ............... cm
Width of the specimen

= ................ cm

Average value = ......................... kg/cm

Model calculation :
Flexural strength

.............. kg/cm

Result :
Flexural strength of the given specimen

............. kg/cm.