MEC 211 Unified Mechanical Engineering I

LABORATORY MANUAL
MEC211 Unified Mechanical Engineering I

2010-2011

MEC 211 Unified Mechanical Engineering I

Table of Contents

SL No Experiment 1 2 3 4 5 6 7 To conduct tensile test on mild steel and cast iron specimens. To conduct Impact test on mild steel and cast iron specimens. To conduct Torsion test on mild steel and cast iron specimens. To find out stiffness of spring and modulus of rigidity of spring wire material. To study tensile strength using strain gauge based cantilever beam apparatus To study torque pick up and torque Measurement using Strain gauges Comparison of measurements of test specimens using micrometer , vernier calliper & height gauge Measurement of surface roughness Measurement of gear profile Measurement of critical parameters of external threads. Measurement of eccentricity angle run out of a shaft To prepare a thermocouple and and its calibration

Page No 3 to 4 5 to 6 7 to8 9 10 to 11 12 to 13 14 to 15

8 9 10 11 12

16 17 18 19 20

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MEC 211 Unified Mechanical Engineering I

Experiment: 1 1.Experiment: To conduct tensile test on Mild steel and cast iron specimens Equipment to be used: Universal Testing Machine, Specimen of MS & CI, Scale, Vernier caliper 2.Learning Objective: To provides information related to the strength and ductility of metals under direct tension stress. 3.Procedure:Measure the original length and diameter of the specimen. The length may either be length of gauge section which is marked on the specimen with a preset punch or the local length of the specimen. Insert the specimen into test machine. Begin the load application and record load Vs elongation data. Measure elongation values with the

help of dividers and a ruler. Continue the test till fracture occurs. Measure the final length and diameter of specimen. 4.Scope of results to be reported: Parameters: A) Original dimensions: Length= ----------------------

Diameter= ---------------------Area= B) Final Dimensions: Length= --------------------------------------------

Diameter= ----------------------Area= Plots: Draw a graph: Stress Vs Strain and identify yeild point, ultimate tensile strength and E and % elongation and % reduction in area. . ------------------------

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MEC 211 Unified Mechanical Engineering I Average breaking Stress = 1. Ultimate Stress = 2.Average Percentage Elongation = 5.Cautions: If the strain measuring device is an extensometer it should be removed before necking begins. Measuring deflection on scale carefully and accurately.

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Experiment: 2

1.Experiment: To conduct impact test on mild steel and cast iron specimens. Equipment to be used: impact testing machine, Specimen of MS & CI, Steel. 2.Learning Objective: An impact test signifies toughness of material that is ability of material to absorb energy during plastic deformation. Static tension tests of un-notched specimens do not always reveal the susceptibility of a metal to brittle fracture. This important factor is determined by impact test. Toughness takes into account both the strength and ductility of the material. Several engineering materials have to withstand impact or suddenly applied loads while in service. 3.Procedure: A) Izod Test:

When the striking hammer (pendulum) in safe test position. Put the steel specimen notch face on impact testing machines anvil in such a way that the 75% inside and 25% above the top surface to its top most striking position

the hammer and is

of the slot .Bring the striking hammer

unless it is already there and lock it at that position. Bring indicator of the machine to zero. Release the hammer, It will fall due to and break the by the specimen through its momentum, the total energy is not gravity absorbed

specimen, the indicator stops moving, while the pendulum falls back. Again bring the hammer to its idle position and back.

B) Charpy Test:

With the striking hammer (pendulum) in safe test positions, put the Steel specimen on impact testing machine anvil in such a way that the notch faces opposite the hammer. 2010-2011 5

MEC 211 Unified Mechanical Engineering I Bring the striking hammer to its top most striking position. Bring indicator of the machine to zero.Release the hammer. It will fall due to gravity and break the specimen through its momentum, the total energy is not absorbed by the specimen. Then it continues to swing. At its topmost height after breaking the specimen, the indicator stops moving, While the pendulum falls back. Note the indicator at that topmost final position.

4.Results Required

a. For Izod Test: Note the indicator at the topmost final position. Calculate energy. b. For Charpy Test: Note the indicator at the topmost final position. Calculate energy. 5.Caution: Measure the dimensions of the specimen carefully. Hold the specimen firmly. Take the readings carefully.

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Experiment: 3

1.Experiment: To conduct Torsion test on mild steel and cast iron specimen. Equipment to be Used: A Torsion testing Machine, Twist meter for measuring angle of twist, A steel rule and Vernier caliper or micrometer 2.Learning Objective: A torsion test is quite instrumental in determining the value of rigidity (ratio of shear stress to shear strain) of a metallic specimen. The value of modulus of rigidity can be found out through observations made during the experiment by using the torsion equation:

Where, T = Torque applied Ip = Polar moment of Inertia C = Modulus of rigidity I = Gauge length l = gauge length

In the torque equipment one end of the specimen is held by a fixed support and the other end to a pulley. The pulley provides the necessary torque to twist the rod by addition of weights (w). The twist meter attached to the rod gives the angle of twist. 3.Procedure: 1.Prepare the testing machine by fixing the two twist meters at some constant lengths from fixed support. 2.Measure the diameter of the pulley and the diameter of the rod and take the average. 2010-2011 7

MEC 211 Unified Mechanical Engineering I 3.Set the maximum load pointer to zero. 4.Set the protector to zero for convenience and clamp it by means of knurled screw. 5.Carry out straining by rotating the hand-wheel in either direction. 6.Add weights in the hanger stepwise to get a notable angle of twist for T1 and T2. 7.Then load out to failure as to cause equal increments of strain reading. 4.Plot torque- twist (T- ) graph Read off co-ordinates of a convenient point from the straight line portion of the twist (T- ) graph and calculate the value of C by using above relation. torque

5.Scope of Result and Discussion : Gauge length of the specimen, l = Diameter of the specimen, Polar moment of inertia, d = Ip = .

Modulus of rigidity of the given specimen is _________ N/mm2 The graph between angle of twist and torque for the given specimen is plotted. Cautions: Measure the dimensions of the specimen carefully. Measure the Angle of twist accurately for the corresponding value of Torque.

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MEC 211 Unified Mechanical Engineering I Experiment no 4 1.Experiment: To determine the stiffness of the spring. Equipment to be Used: Spring testing machine, Spring specimen, Vernier Caliper, Micrometer. 2.Learning Objective: To determine the stiffness of the spring.

3.Procedure: 1.Measure the diameter of the wire of the spring by using the micrometer. 2.Measure the diameter of spring coils by using the venire caliper. Count the number of turns, 3.Insert the spring in the spring testing machine and load the spring by a suitable weight and note the corresponding axial deflection in tension or compression. 4.Increase the load and take the corresponding axial deflection. 4.Plot A curve between load and deflection. The shape of the curve gives the stiffness spring. 5.Scope of Results and Discussion : Least Count of Micrometer = Diameter of Spring wire, d= ___________________ ___________________ ___________________ ___________________ of the

Least count of Vernier caliper = Diameter of the spring coil, D =

Mean coil diameter, Dm = D d = _______________ Number of turns, n = ___________________

The value of spring constant of Closed coiled helical spring is ___________ N/mm. Modulus of rigidity is ___________________________

6.Cautions: 1.Measure the dimensions of spring accurately. 2.Note the deflections accurately.

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MEC 211 Unified Mechanical Engineering I Experiment no 5 1.Experiment: To study tensile strength using strain gauge based cantilever beam apparatus. Equipment Required: Digital Voltmeter, Strain gage measurement kit, Standard Cantilever Beam apparatus. Material Requirement: Standard Weight Specimen. 2.Learning Objectives: 1) To learn the working principle of Wheatstone bridge. 2) Determination of strain and stress using strain gages. 3.Procedure 1) Connect the Voltmeter in Wheatstone bridge to calibrate the voltage change. 2) Adjust the resistor to obtain a zero output voltage when the cantilever beam is unloaded 3) Connect the strain gage wire to the strain gage measurement kit to complete the circuit. 4) Now apply the given standard load to the free end of beam. 5) Switch on gage measurement kit and set the current. 6) Note down the voltage for a given load. 7) Increase the load stepwise and note down the voltage respectively.

4.Scope of Expected Results: 1) Calculated result of strain (=(6*P*x)/E*b*t2) should be match with the experimental result (digital display). 2) Draw the Shear force and Bending moment diagram for respective load. 3) Hooke's Law states that for elastic behaviour that the strain is proportional to the load applied, does your graph verify Hooke's Law? 5.Parameters and Plot: 1) Note down the Voltage with respect to the load. 2) To calculate the change in resistance. 3) To calculate the tensile stress. 4) Plot the graph Load Vs Stress. 2010-2011 10

MEC 211 Unified Mechanical Engineering I 5) Plot a graph of output voltage (in Volts) on the vertical axis versus beam loading (in kg) on the horizontal axis. 6.Cautions: 1) Put the load on span very carefully and slowly. 2) Check out the connection of voltmeter to Wheatstone bridge. 3) To maintain the constant power supply. 4)All the connection should be proper channel.

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MEC 211 Unified Mechanical Engineering I Experiment No 6 1.Experiment: To study torque pickup and torque Measurement using Strain gauges. Equipment required: Standard weights, multimeter, Torque measurement kit, and display or data gathering unit Material required: NIL 2.Learning objectives: To study the variation of torque with increase in weight, and measurement techniques for torque.

3.Outline of procedure: Place the torque measurement kit on the table free from any vibration Connect the kit to the display unit Now turn on the display unit Connect the multimeter to the Wheatstone bridge shown on the unit to the display unit Now gently put the weight on the on side in the vertical circular rod and measure the voltage Repeat the above step for different load and measure the voltage Convert the voltage data to torque using appropriate formulae Now compare that torque with the torque displayed on the display unit 4.Scope of the results expected: Student will learn the working of strain gauge and how torque varies with load 5.Parameter and plots: Plot the voltage vs. load.

Torque Measurement:

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MEC 211 Unified Mechanical Engineering I

Wheatstone bridge The output from the Wheatstone bridge can be expressed as:

T = Torque applied = Poisson ratio, E = Youngs Modulus = Strain, = Shear strain F= Gage factor, R= radius of shaft

6.Cautions: Make sure that multimeter is set in the proper range Do not put drop the weight, put is gently Do not exceed the limit of weight on the torque measurement unit High-quality transducers utilizing strain gages as the primary sensing element incorporate sophisticated techniques to minimize thermal effects, nonlinearities, hysteresis, and other sources of error. very accurate gage orientation and placement of all four gages is crucial for success.

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MEC 211 Unified Mechanical Engineering I

Experiment No 7
1.Experiment : Comparison of measurements of test specimens using micrometer and vernier caliper. Equipment & Tool Required: Vernier caliper 6 inch, Micrometer (0-25 mm), Micrometer (25-50mm ),test specimens . 2.Learning Objectives: To perform different operations of Measurement using micrometer and vernier caliper.

3.Out line of Procedure (Part -1) Select and collect instruments as per the specimen given to you .Find out the least count of all the instruments .Take two test specimens and measure all the dimensions (All Diameters as well as lengths,bore size ,bore depth ,thread diameter etc. )Draw the figure both of specimens on the copy and and show all the dimensions .

Procedure Part -II Take any one specimen and measure its dimensions ( length and diameter) using micrometer and vernier calipers and then find out its volume 2010-2011 14

MEC 211 Unified Mechanical Engineering I

Procedure Part -III Take out your instrument (25-50 micrometer) and check its accuracy by using test piece provided in the box (check zero to zero alignment of datum line on barrel and zero of the thimble scale .Take a slip gauge piece of 25 mm and measure it with the given instrument .Take another piece of slip gauge of smaller size and wringer it with 25mm piece so that no air is present in between .then measure the two pieces considering them as one piece .If the reading matches with the size written on the slip gauge block then your instrument is correct . Observation : 1. Measurement using vernier caliper. 2. Measurement using micrometer. Error Analysis :1. Take any one dimension and measure it with both micrometer and vernier caliper,then do the error analysis . 2. Error =Measurement taken by micrometer(Actual size) Measurement taken by vernier caliper(measured size) 3. Relative error = (Actual size) (Measured Size) Actual size

% error = Relative Error x 100 4.Results required: : 1. Understand the principle and working of vernier caliper and micrometer. 2. Understand the difference in accuracy of measurement by vernier caliper and micrometer. 3. Select the instrument for the measurement of given work piece. 4. Calculate least count of the instrument and note down the readings. 5. Judge the required measuring pressure during measurement. 5.Caution : 1. There should not be any play between sliding jaw & the main scale. 2. Check the instruments for zero error. 3. Parallax or reading error must be avoided. 4. Do not apply undue pressure. 5. Handle instruments carefully as those are very sensitive esp. Taking care of not let them fall anywhere

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MEC 211 Unified Mechanical Engineering I Experiment No 8

1.Experiment 8: Measurement of surface roughness . Equipment & Tool Required: Portal Surface roughness tester, test specimen etc. 2.Learning Objectives: To study degree of roughness of various machining process. 3.Procedure: Take the measurement at various places and also in multiple directions. Some operations can produce direction dependent roughness .Make a drawing in first angle projection and mention all the dimensions and surface criterion. 4.Results Required:: 1. 2. process. 3. 5.Cautions: 1. 2. 3. 4. 5. Understand the difference in all types of surface roughness factor. Understand and differentiate work pieces produced by different machining Understand the principle and working of surface roughness tester. Always wear shoes while performing the practical Always wear lab coat. Do not try to touch any machine without the permission of workshop in charge. Remove any oil and grease etc. from the surface. Place the probe gently on the measuring surface.

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Experiment No 9
1.Experiment 9: Measurement of gear profile Equipment & Tool Required: Vernier

1. 2. 3.

caliper : 0 150 mm Micrometer : 0 25 mm, 25 50 mm Sample gears(Spur ,bevel,Helical and Worm gears ) Profile projector study the elements of gear

2.Learning Objectives: To 3.Procedure: Take the

gear and clean It for removal of any dust or dirt.Take the vernier and measure its outer dia ,Thickness ,inner dia of hole .Place the gear on profile projector and measure all its dimensions like addendum, dedendum ,pitch circle diameter.Compare the measurements with the standard calculated data theoratically
4.Results Required:

1.Measurement using vernier caliper 2.Measurement using profile projector 5.Caution : 1. There should not be any play between sliding jaw & the main scale. 2. Check the instruments for zero error. 3. Parallax or reading error must be avoided. 4. Do not apply undue pressure. 5. Handle instruments carefully as those are very senstive esp. Taking care of not let them fall anywhere

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Experiment No 10
1.Experiment 10: Measurement of critical parameters of external threads. Equipment & Tool Required: Thread micrometer, Anvil set 2.Learning Objectives: To 3.Procedure: Take the

study the elements of gear

gear and clean It for removal of any dust or dirt. Take the vernier and measure its outer diameter, Thickness, inner diameter of hole .Place the gear on profile projector and measure all its dimensions like addendum, addendum, pitch circle diameter. Compare the measurements with the standard calculated data theoretically 4.Results Required:Measurement using vernier caliper Measurement using profile projector
Scope of the Result to be reported:

Understand the principle and working of profile projector. Understand the difference in measurements taken by profile projector and vernier calipers

5.Cautions:

1. There should not be any play between sliding jaw & the main scale. 2. Check the instruments for zero error. 3. Parallax or reading error must be avoided. 4. Do not apply undue pressure. 5. Handle instruments carefully as those are very sensitive esp. Taking care of not let them fall anywhere.

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Experiment No 11
1.Experiment 11: Measurement of egocentricity angle run out of a shaft Equipment & Tool Required:

DTI (Dial Test Indicator) with stand, surface plate, V- blocks, Bench center, Height Gauge Specimen work pieces 2.Learning objectives:-To learn how to measure the eccentricity

3.Procedure:
For measuring Straightness Measure the Diameter of given shaft with the help of a micrometer. Hold the parallel shaft in the centers of bench center .Set the height gauge at the center height with the centers of bench center .Mark a straight line on the piece .Rotate the piece by 360 degree. Mark another line on work piece .Both the lines should be parallel to each other. For measuring eccentricity :Hold the piece in between centers of a Bench center .Mount a dial gauge on the magnetic stand. Set the dial to zero degree with its plunger loaded on the job. Rotate the piece with hand and check and note any deflection in DTI. If No deflection, it means there is no eccentricity in the piece. Same operation can also be done carried out by holding the job on a V block and holding it with a clamp.
4.Results Required: Tabulate the difference in readings and find out deviation from basic size by plotting a graph. 5.Cautions: Always wear shoes while performing the practical. Do not wear bangles, bracelets, rings, chains, and even neck tie. Always wear Lab coat (white). Always wear safety goggles. Do not lean on to the machines. Follow the operative instructions given strictly

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MEC 211 Unified Mechanical Engineering I

Experiment No 12

1.Experiment 12-: To prepare a thermocouple and its calibration Equipment & Tool Required:- Mille voltmeter,PT-100 meter, J thermocouple meter, Connecting Wires Thermocouple wire,PT-100 Thermocouple, J type thermocouple, Thermometer, Heater, pan etc 2.Learning Objectives:- Preparation of thermocouple and its use for different range of temperature
3.Procedure:Take thermocouple wires and twist them with each other to for m a thermocouple Connect the other ends to the measuring meter .Connect all the parts as per circuit diagram .Start insert the heater and let the water to be heated up to 80-90 degree and then switch off the heater. the thermocouple and thermometer in the heated water; make sure that both thermometer and thermocouple are not touching the base of the container .Take 10 readings after every minute Compare the readings of thermometer and thermocouple .Plot the graph between time and Temperature for both the readings of thermometer and thermocouple. Take standard thermocouple instead of thermometer and repeat steps .Compare the two graphs

3. Result Required:
1 To know the working of a thermocouple 2 Compare readings of j type and PT -100 type thermocouple

4.Cautions
1 There should not be any play between sliding jaw & the main scale 2 Check the instruments for zero error 2010-2011 20

MEC 211 Unified Mechanical Engineering I 3 Parallax or reading err or must be avoided. 4 Do not apply undue pressure 5 Handle instruments carefully as those are very sensitive especially taking care of not to let them fall under any circumstance

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