Instructor : Prof. Dr.

Omar Badran

Prepared by:
Dr. Naseer Ahmed
Department of Mechanical Engineering
College of Engineering, Taibah University
Department of Mechanical Engineering

ME-321 Manufacturing Process I

ME 321
Manufacturing
Process I

Mechanical Properties of Materials

Department of Mechanical Engineering

ME-321 Manufacturing Process I

Mechanical properties of a material determine its

behavior when subjected to mechanical stresses.
These properties includes
Elastic Modulus
Ductility
Hardness
Various Measures of Strength

It is helpful for the manufacturing engineer to

appreciate the design objective and for the designer
to be aware of the manufacturing objective

Department of Mechanical Engineering

ME-321 Manufacturing Process I

Mechanical Properties
that are desirable to the designer,
such as high strength, usually make the manufacture of the
product more difficult.

Stress-Strain Relationship

Department of Mechanical Engineering

ME-321 Manufacturing Process I

Three types of static stresses

Tensile Stresses: tends to stretch the material
Compressive Stresses: tends to squeeze it
Shear stresses: tend to cause adjacent portions
of the material to slide against each other.

Stress-Strain Graph

Strain by e = (L - Lo)/Lo
e = E e (E = Modulus of Elasticity)
Important Terms
Yield Stress
Ultimate Strength
Fracture Stress (Stress immediately before
fracture)

Department of Mechanical Engineering

ME-321 Manufacturing Process I

Stress is given by

Sample
ME-321 Manufacturing Process I

Department of Mechanical Engineering

Tensile Testing Machine

ME-321 Manufacturing Process I

Department of Mechanical Engineering

Stages
ME-321 Manufacturing Process I

Department of Mechanical Engineering

Plot
ME-321 Manufacturing Process I

Department of Mechanical Engineering

More terms

Department of Mechanical Engineering

ME-321 Manufacturing Process I

Ductility: The ability of a material to plastically strain

without fracture.
Elongation : EL = (Lf Lo) / Lo
Area reduction: AR = ( Ao Af ) / Ao

Types of Stress-Strain Relationships

Department of Mechanical Engineering

ME-321 Manufacturing Process I

(a) Perfectly Elastic

This material fractures rather than yielding to
plastic flow. Brittle materials such as ceramics
and cast irons are good examples.

Types of Stress-Strain Relationships

Department of Mechanical Engineering

ME-321 Manufacturing Process I

(b) Elastic and Perfectly plastic

Once the yield strength Y is reached, the materials
deforms plastically at the same stresses levels.
Metals behave in this fashion when they have been
heated to sufficiently high temperatures that they
re-crystallize rather then strain harden during
deformation. Lead exhibits this behavior at room
temperature

Types of Stress-Strain Relationships

Department of Mechanical Engineering

ME-321 Manufacturing Process I

(c) Elastic and Strain Hardening

Examples are ductile metals when cold worked.

Bending and Testing of Brittle Materials

Department of Mechanical Engineering

ME-321 Manufacturing Process I

Hard brittle materials, which posses elasticity but

not plasticity, are often tested by method which
subjects the specimen to bending loads.
Also known as the three-point test
The strength value derived from this test is called
Transverse Rupture Strength (TRS)
TRS = (1.5 F L ) / (bt2)
TRS in MPa: F in N: L in mm: b and t in mm

Bending test equipment

ME-321 Manufacturing Process I

Department of Mechanical Engineering

Shear Properties

Department of Mechanical Engineering

ME-321 Manufacturing Process I

Shear involves application of stresses in opposite directions

on either side of a thin element to deflect it. Given by
=F/A
Shear Strain is given by
=/b
Units of strain are given in terms of in/in or mm/mm
= (Deflection of the material, mm)
b = (Orthogonal distance across which the load is applied,
mm)

Torsion Test Setup

Shear strain,

R
Where is the angular deflection (radians)
L

Department of Mechanical Engineering

ME-321 Manufacturing Process I

Shear stress,

Hardness

Department of Mechanical Engineering

ME-321 Manufacturing Process I

The hardness of a material is defined as its

resistance to permanent indentation.
Good hardness generally means that the material is
resistant to scratching and wear
For many engineering applications, including most
of the tooling used in manufacturing, scratch and
wear resistance are important characteristics

Hardness Tests

Department of Mechanical Engineering

ME-321 Manufacturing Process I

These are commonly used for assessing the material

properties because they are quick and convenient.
A variety of testing methods is appropriate due to
differences in hardness among different materials
among different materials.
Types are
Brinell Hardness Test
Rockwell Hardness Test
Vickers Hardness Test
Knoop Hardness Test
Scleroscope
Durometer

Brinell Hardness Test

HB

2F
(Db )( Db Db2 Di2

F = indentation load (kg)

Db = diameter of the ball (mm)
Di = diameter of the indentation on the
surface (mm)
HB = Brinell Hardness number (kg/mm2)
Department of Mechanical Engineering

ME-321 Manufacturing Process I

This test is widely used for testing metals and nonmetals of

low to medium hardness.
Named after Swedish engineer who developed it around 1900.
A hardened steel ball of 10-mm diameter is pressed into the
surface of a specimen using a load of 500, 1500 or 3000kg.
The Brinell hardness number (HB) is then given by

Rockwell Hardness Test

Department of Mechanical Engineering

ME-321 Manufacturing Process I

Named after the metallurgist who developed it in early 1920s

A cone-shaped indenter or small-diameter ball (1/16 or 1/8-in
diameter) is pressed into the specimen using a minor load of
10kg, thus seating the indenter in the material.
A major load of 150kg is then applied, causing the indenter to
penetrate into the specimen a certain distance beyond its
initial position.
This additional penetration distance d is converted into a
Rockwell hardness reading by testing machine.

Vickers Hardness Test

Department of Mechanical Engineering

ME-321 Manufacturing Process I

This test uses a pyramid shaped indenter made of

diamond.
Loads of various sizes are applied, depending on the
hardness of the material to be measures.
Vickers hardness (HV) is determined from the formula
HV = (1.845F)/(D2)
F= applied load (kg)
D = the diagonal of the impression made by the indenter
(mm)

Knoop Hardness test

Department of Mechanical Engineering

ME-321 Manufacturing Process I

This test uses a pyramid-shaped diamond indenter, but the

pyramid had length-to-width ratio of about 7:1.
The applied loads in knoop test are lighter than in the vicker
test.
Suitable for measuring small, thin specimens or hard materials
that might fracture if a heavier load were applied.
HK = (14.2 F)/(D2)
F = load (kg)
D = Long diagonal (mm)

Scleroscope

Department of Mechanical Engineering

ME-321 Manufacturing Process I

An instrument that measures the rebound height of a hammer

dropped from a certain distance above the surface of the
material to be tested
The hammer consists of weight with diamond indenter
attached to it
This measure the mechanical energy absorbed by the
material when the indenter strikes the surface
The energy absorbed gives an indication of resistance to
penetration, which matches the definition of hardness.
If more energy will be absorbed, the rebound will be less,
meaning a soft material and vice versa.

Durometer

Department of Mechanical Engineering

ME-321 Manufacturing Process I

All previous test were based on resistance to permanent or

plastic deformation (indentation).
The durometer is a device that measures the elastic
deformation of rubber and similar flexible materials by
pressing an indenter into the surface of the object
The resistance to penetration is an indication of hardness.

Effect of Temperature on Properties

Strength and ductility

Tensile
Strength

Yield
Strength
Ductility
(% elongation)
0

Department of Mechanical Engineering

Temperature

ME-321 Manufacturing Process I

Temperature has a significant effect on nearly all properties of

material
At elevated temperatures, materials are lower in strength and
high in ductility
Most materials can be formed more easily at elevated
temperatures than when they are cold

Hot Hardness

Department of Mechanical Engineering

ME-321 Manufacturing Process I

A property often used to characterize strength and hardness

at elevated temperatures is hot hardness
Hot hardness is simply the ability of the material to retain
hardness at elevated temperatures; it is usually presented as
either a listing of hardness values at different temperatures or
as a plot of hardness versus temperature.
Good hot hardness desirable in the tooling materials used in
many manufacturing operations. Significant amount of heat
energy are generated in most metal working processes, and
the tools must be capable of withstanding the high
temperature involved.

Re-crystallization Temperature

Department of Mechanical Engineering

ME-321 Manufacturing Process I

Most metals behave at room temperature according to the

flow curve in the plastic region. As the material is strained, it
increases in strength due to strain hardening.
but if the metal is heated to a sufficiently elevated temperature
and then deformed, strain hardening does not occur.
Instead new grains are formed that are free of strain, and the
metal behaves as a perfectly plastic material.
The formation of strain-free grains is a process called recrystallization, and the temperature at which it happens
(nearly one half of the melting point) is called the recrystallization temperature.