FACULTY OF ENGINEERING, D.E.l. Material Testing Lab. Instruction Sheet Impact Test To study the Izod's Testing Machine and to find out - 1. Impact value of mild steel, copper and Brass specimens 2. the striking velocity of the swinging pendulum 3. the weight of swinging pendulum K & 4. length of ewinging pendulum Apparatus Used v ‘Specification Shea: Formula Used 4. Length of pendulum L a 2 L=+x ar * g eee aoe where, t = Time Period of one oscillation in seconds L= Length of pendulum in meters 9 = Acceleration due to gravity in meters / second” 2. Height of fall, h h=L-Loos 60°inmeters = 0. Gro 3. Weight of pendulum W in kg Potential energy = capacity of machine ‘Wh = 16.6 kgm 4. Striking velocity, V V=,2gh inmetersisec = 3-42 ™ &e Description ‘The machine consists of a base casting upon which are erected two rigid A frames. Between the apexes of these frames is a pendulum mounted in ball bearing in such a way that all lateral movement is prevented. The pendulum consists of a hammer which holds a striking edge. A vice is provided on the base in such a way that the standard specimen Is fixed. Knife edge of the swinging pendulum strikes the test piece at the proper place. The pendulum is released from the standard height by means of a trigger. A pointer is arranged to move with the pendulum when it is released and leave it at the maximum height which the pendulum reaches after striking the specimen. The pointer indicates the energy absorbed by the specimen (izod impact Value). Procedure 1. Place the specimen in the vice with the help of the positioning gauge. 2. Raise the pendulum to its maximum position over the trigger and bring the pointer to read 16.6 kgm on the right end. 3. Release the trigger. The specimen and its lower point hit the specimen and break or bend it. Hold the pendulum when it swing, back and keep it on the rest bar. 4. coals pointer. The pointer now gives the energy lost in rupturing the specimen.Observations = Table! N Material Impact Value “Type of fracture (Ductile oF Brittle) IL ms 16-3 Direraee 2 MS qt Or | | Tabl SN. Wo. of oscllations eo Time Taken Thedimepsriod 1h 10 Bt. QA 2 1G DAIS | QOD 3 iD BR a 24 Specimen Calculations (Reading No.) Result Conclusion (Discuss type of fracture) Sources of Errors Precautions Questions ~ 8. 4. What is the meant by Izod’s Value? 2. What do you understand by ductility? 3, Whatis brittleness? 4. §, 6. What is the angle of Notch in the test specimen and how does it effect the hardness? . Give the name of similar impact test, how does it differ from izod's Test. - What is the object of providing a notch in Izod Impact Test specimen? Why this notch should be in tension? | What is the property of the material that is compared in the impact test? What are its units? Give the advantages for the bolt of uniform strength. Diagrams 1. 2. Dimensioned sketch of the standard specimen. ‘Skeleton diagram of the Izod’s Impact Testing machine.FACULTY OF ENGINEERING, D.E.I. Material Testing Lab. Instruction Sheet Cement Test Object To study the Cement Testing Machine and to find the tensile strength of the standard briquette. Theory ‘Write in your own word's explaining the following - 1, Composition of cement 2. Functions of the components of concrete and their composition 3. The three tests for acceptance of cement a) soundness b) time of set ¢) strength of mortar 4. The composition and method of preparation of the briquettes tested Description The machine consists of a steel yard mounted over a knife edge on a pillar. This is connected to the upper holder of the grips through a system of leaders. The lower holder is connected to a hand-wheel which enable it to be moved up or down of tightening and removing the specimen. At one end of the steel yard, there is a receiver of lead shot, falling from a container above. The outlet for the lead shot is governed by @ valve which will close automatically as the briquette gives way. The other end of the steel yard holds a cheese with adjusting nuts which is used to balance the yard initially. The load at which the specimen ruptured is easily obtained by weighing the lead shot in the receiver through the proper system of levers and using the proportional weight supplied for the purpose, the exact weight below 100 Ibs. (upto'an accuracy of 1 Ib) can be known by means of a rider over the steel yard moving over a scale of 100 Ibs. Procedure The specimen is prepared in the mould provided according to the method described. The receiving container on the steel yard is emptied of all the shot. The grips are adjusted to the correct height and the specimen is placed in position. The steel is brought to the balance position, the shot valve is opened and an even and steady application of load is obtained at a speed of 100 Ibs in 12 sec. (specifications BSS no. 12/1947). When the specimen breaks the flow of shot is automatically stopped by the fall of the steel yard operating a trigger. The shot receiving container is then suspended at the other end of the yard and weighted. This gives the load in Ib. at which the ‘specimen was fracturedObservation Sheet Testin 1. Type a) type of stress in specimen b) method of load application ©) method of load measurement 2. Capacity 3. Make Observations Area of cross section of the Briquetts S.N. Curing Period ‘Load Tensile Strength Precautions Conclusions Questions |. What is the composition of cement? 2. What do you understand by reinforced cement concrete and why is concrete reinforced? 3, How does the following factors affect the strength of concrete:- a) the water cement ratio b). the age 4. For given water cement ratio which is more economical a stiff mixture or a thin one. 5. What are the requirements of ISI regarding the strength of cement? @. What is the necessity of adding Gypsum in the manufacture of cement? DiagramsFACULTY OF ENGINEERING, D.E.I. Material Testing Lab. Instruction Sheet Torsion Test Object To perform the torsion test on a supplied specimen of a material on the Torsion Testing Machine and to determine the following - i) Draw graph between torque and angle of twist ii) To determine the modulus of rigidity for a material of a __ specimen iii) To determine the shear stress of specimen Apparatus Specifications where, T = Torque applied on the specimen in kg-m olar Moment of Inertia G = Modulus of Rigidity 8 = Angle of twist in radians L = Length of specimen in meters Shear stress R = Radius of specimen Procedure 1. The specimen is adjusting into the holes provided for the purpose. At this time, the angle of rotation is zero. There may be error due to which the dial which is divided into 360° will not show the zero position. The error is elimination while taking reading. One end of the specimen is fixed and the other end is connected to the handle through gears. . Torque is applied by rotating handle which is observed in the vernier provided on the machine itself. N e &4. Reading is taken after each 10 degrees of rotation of the dial and the corresponding torque is observed simultaneously. 5. Readings are taken until the specimen breaks. Observations Diameter of the specimen = Length of specimen = Polar Moment of Inertia = SN ‘Angle of Rotation Torqueinkg—m_| 2. 3. | Calculations Result Questions 4. Show by means of diagrams the type of fracture that shail be obtained in a torsion test in following test in following cases. i) Cast Iron ji) | Low Carbon Steel iii) Thin tabular specimen of a ductile material 2. Derive the formula used to calculate the modulus of rupture in case of solid rod in torsion. State the assumptions made in deriving the formula. 3. What name is given to fracture on Cl specimen in torsion test? Explain its formation. 4. Give the sketch for specimen which shall be used to determine yields point in shear with proportional for its sizes in terms of diameters. 5. What precautions are necessary in preparing the torsion test in case of a hollow specimen if it is to be held in a machine where holding device is a chuck? . What is a permanent set and percentage elongation? What is the difference between plasticity and elasticity? ' Derive an expression. for the shear strain energy of rod subjected to torsion under stress (below yield point) can be given by the formulae. OND TL “7G,FACULTY OF ENGINEERING, D.E.\. Material Testing Lab. Matar ing Lab. Instruction Sheet Spring Test To observe the behavior of ° r of a helical spring under deflection characteristic and to find the folowing teach otine epange, (@) Stiffness of the spring (Modul lus of the spri ® ood he rgity (Shear Modulus ot the material ofthe spring) apa kb Shaar sons inthe spring at maximury load, ‘Specifications Theory (Formula Used): For a helical spring, following formula can be used 4. Modulus of spring (ettinese),5 = S477R'n ° Gd" Stiffness = W/S for both types of springs. 2. Modulus of Rigiaty (@) = £47 Rin Ax For compression spring ‘C’ wD, 3. Shear Stress at max. load for both tension and compression springs, f, = 02 where, 6 Wis the total load and being total deflection are the deftection against load Wy We G Modulus of rigidity R Mean Coil Radius Ni: & Ne No. of coils d = wire diameter Description ‘The spring testing machine consists of two hooks in which the spring (tensicn spring) to be tested is mounted. The upper hook is attached to a lal gauge whic? wil seri Ghe load applied on the spring. The lower hook js carried on a cross head sling rea 0 vertical column firmly fixed to a rigid base. The cross heed can be raved WP or Jean by moving the hand lever. Compression springs are placed betwoen the two Tuer plates the upper plate of which is the cross head itself and the, ower plates tomet the epring is placed is attached tothe dial gauge which reads appiog re ert feaction in both cases can be measured on the scales attached on the tight and teft one of which reads from top to bottom and the ‘other from bottom to top. Tight are head can be fixed at any desired postion initially according to the free length of the spring. Procedure . (C) Place the spring (tension spring) in the upper hook and adjust the cross head to cuit the length of the spring and attach the lower Nook also, {Q) Note the reading on the defection scale when the dial gauge just starts to move as the loading handle is slowly moved down. (3) Gradually applied the load in 8 to 10 ‘herements and note the deflection scale reading. 4) ‘Kner teaching the maximum toad (ay 30 Kg) reduces in the same manner and read the vernier. . 1 < | | , J . a(8) Tabulate the readings in the given order and draw graph between load and deflections for each spring. (6) Measure the outside diameter and wire diameter by means of calipers. Construct a load deflection graph with loads 8 ordinates distinguish between points of loading an unloading but draw a single straight line as a mean for the entire zone k of points. Observations A. For Compression Spring Mean coil dia = 2+ Pi Mean wire di Ase No. of coils = Ny ‘Spring under compression ie increasing | Decreasing | Mean shear sn. | '9eg\'n | Vemier Scale | Vernier Scale | Stifness | Modulus earn) Reading Reading (in Kg/ cm) | (in Kg/ em) inom) (nem) B. For Tension Spring Mean coil dia = Bae Mean wire dia = Pee No, of colls = N, Spring under somoresion increasing | Decreasing | _Mean Shear SN. | (tOR8) | Vemier Scale | Vernier Scale | Stifness | Modulus eek ora Reading Reading | (in Kglom) | (in Kgl em) (nem) (inom) | | = ‘Specimen Calculations Results Precautions Source of Errors Questions 1. What do you mean by stiffness of spring and what its units? 2. What type of energy is stored by the spring under load and what is its magnitude? 3. How many and what type of loads is generally applied on springs? 4, State the difference between closed coil and open coiled helical springs? 5. State important types of springs generally used in practice? 6. What type of springs generally used in automobiles and in railway wagons? 7. What types of springs are used in clocks for winding? Can the same spring be used for alarm purposes? 8. On what factors the stiffness of the spring depends? 9. Write down the expression for deflection due to open colléd spring subjected to axial load only in terms of helix angle. Diagrams ¢ ? aFACULTY OF ENGINEERING, DE. Material Testi tS Material Testing Lab Instruction Sheet Tensile Test To study the Hounsfield Te the given specimen and find out fensometer and to perform the tensile test on @) upper yield (i) lower yield point (v) percentage elongation ) ultimate strength (W)pereentage reduction in (iv) “breaking Apparsecs 19 strength pean neta ‘Tensometer, Mild Steel specimen, graph paper, gauges ete. Hounsfield Tens Harland Road, Grayion Ree tees 16902 Tensometer Ltd. 81, es ‘The Tensometer is a gear type universal testing machine. It of two columns at one end of which spring beam rests on the roller supports, The tension head fe connected to the centre of the spring beam. test piece can be chucked. The other end of the test piece is chucked to the cross head which slides and is moved by a nut fixed at the other end of the two columns. The nut can be rotated by a handle through a worm. The deflection of spring beam (which is proportion to the load) applied on the test piece is transmitted to a plunger in a mercury cylinder which pushes Hg in tube. A scale by the side of the tube is graduated to read the load in tension in Kg. The moment of screw is transmitted to drum through gears magnification strain of 16.8, 4, 2, 8, 1 are provided. An autographic record of the tension be obtained on the graph mounted on the drum attachment are provided with mic for compression and bending test. Theory Tensile test results of various engineering material enables structural engineering designers, production engineers and manufacturing concem to incorporate the mechanical properties material to their consumption economically. In addition to metal tensile fabrics, plastics fibres, wood, plywood and rubber. The tensile test depends upon () Elastic limit (ii) Limit of elasticity is the highest stress to which the Young's modulus of elasticity specimen is capable of developing without any permanent set. Young's Modulus of Elasticity Mt can be defined as the ratio of the stress increased to the correspondent strain increment in the elastic stress line zone of stress. Proof Stress Tt is the stress which is just capable of any strain curve sufficient to cause a permanent set equal to the specified percentage of the original gauge length marked on the test piece, Modulus of Resilience This is the amount of energy stored per unit volume of stressed material when it is stressed to the elastic limit can be determined by using Suitable scale for lead Vs equation curve as the area under the curves and ay elongation axis up to the end within elastic limit. ) 1 | ¢Actual Stress The stress is found on dividing th ie cross section, which Is ordinary, ‘done. The reseed 2 ens . Actual Stress = ———_TrueLoad : fseebiny ene Actual cross section area t pecial case of ductility which qualit eabilty I ich qualitatively indicated a atari ity to be hammered and worked particularly their sections or Brittle and-Ductilo Fractures Iti A it is obtained when testing of brittle metal 2S one in whic the movement of crack enables very little plastic deformation ot “ adjacent to the crack. Ductile fracture is one which ‘spreads as result of int i i ti i Sf. igtensive localized plastic deformation of the metal just at the tip of the Procedure 1. Set percentage elongation and percentage of reduction gauge with test pi . 2. Mount the test piece on the mic using proper cracks. 2 bead the graph paper on the drum, the arrow on the graph coinciding scale in flange of the drum in position after adjusting the position to be given proper magnification, . Rotate the hand wheel, the Hg just starts rising in the tube. . Adjust the pin to coincide with strain axis press the pin to start. . Rotate the handle of revolution every time and after adjusting the level of Hg, press the pin. Proceed in this way until test piece breaks. . 7. ee test piece breaks measure % elongation in length and % reduction in Observations {i) Specimen is made of mild steel. (ii) There is only one yield point. Result The force Vs elongation graph is drawn for the given mild steel specimen which has only one yield point. i Precautions (i) Load should be increased gradually. (i) Marking of Hg should be pointed with the help of glass. (il) Yield point reading should be taken carefully. Sources of Errors . @ The load may not be increased gradually. (i) The yield point may not be noted carefully. Questions 4. What do you understand by upper and lower yield points? How the existence of these can be explained in case of test of mild steel specimen? What is the cup and cone fracture? Explain its formation. Explain briefly the difference between plastic range and elastic range. What is the difference between ductile and brittle fracture? Define the modulus of resistance? Define the yield point, elastic limit and ultimate strength? Draw stress diagram for (i) MS., (il) C.l., (lil) Cu. |. Differentiate between - w@ proof stress (i) __ tensile stress of MS specimen. Pan ONAASONFACULTY OF ENGINEEERING, D.EJ. Material Testing Lab. Object To study the Rockwell Hardness Testing M avon osu the Rocke ‘esting Machine and to find the Hardness of Seen epecirane |, cast-iron, Mild-steel, Brass, High Carbon Steel). Specifications ‘Hardt i ardness is the property of materials b i istance sca rare ange tty oer mae ene ate , eo eas under examination is indented by another body, to indenting too! used in the Rockwell machine is either a polished cone fe diamond with vertex with angle of 120 degree and a round point or a Hardness steet ball but the latter is employed only for material having a Brinell fardiness less than 250 or Rockwell hardness less than 130 on scale B. the ‘The depth of the impression made by the diamond cone (or the steel ball) in dire. ay ter being tested is indicated by the pointer on a dial and the scale read trectly the Rockwell Hardness Number. Since the depth is greater for soft material iF in for hard, it might seem than the reading indicates softness rather than the lardness, but by arranging the numbers on the dial decrease in the direction in which pointer moves the reading can be made to indicate hardness. The two loads used ig the test are known as minor and major loads. The minor load which is 10 Kg is applied first to take up any spring and buck lash in the machine to eliminate the effects on the final readings of surface imperfections in the object under test and to provide a datum for hardness measurement. The dial is adjusted so that the pointer is at the set position. Next, the major load is applied and then removed, leaving the minor load on the specimen and the reading on the dial will be the Hardness Number. There is partial recovery in the depth of impression when major load is temoved and it is the remaining part of depth caused by this load which settles the Position of the pointer. Since, the minor load is the only load on the specimen after the test impression has been made, any error due to deflection in the machine itself is avoided, The standard minor load is 10 kg. The scales A and C are used with diamonds cone and read from 100 to 0. With A the major load is 50 kg and with C it is therefore the total loads are 6 kg and 150 kg respectively, The scale B is used with 1/16" diameter steel ball and reads from 130 to 0. The major load is 90 kg making a total of 100 kg. Irrespective of the size of balls and the major loads the red figures (or the B scale) is read if ball indentors are used in the test and black figure (or the scale) for the brass (diamond cone penetrator). In the operation of the machine a minor load of 10 kg is first applied which causes an initial indentation thats steel the indentor on the material (the final hardness is also read with minor load on) the dial is set at zero on the scale and the major load applied. After keeping it for the prescribed time it is removed and the dial is read minor load acting through the penetrator. Rockwell Hardness Number are read directly on the indicator as explained before and are derived from measurements of depth of impression is the following manner. Ha = E-0 : where is the difference between depth of penetration before and after the application of major load and while the minor load is in operation in both cases. The value of k is expressed in units 8 and 100 on scale C i.e., Instruction Sheet Rockwell Hardness TestRockwell B under Hye = 120-Pepth of penetrsion(mm) Rockwell C under Fig = 100 Depth of penetration (mm) 0.002, ‘A Rockwell Hardness Number can also be designated by Hr and then peropriate letter indicating the scale to which it refers e.g., Hrc 40, which ‘cstnes ¢ ckwell Hardness of 40 unit determined on C scale. The scales to be used for different msterials are given in table below - Penetrator Scale Value of E ] Major Kg | Minor Kg | Total | Material for which - Kg scaleis used _| A_ [Diamond | Too 80 10 60 | Thin hardened cone steel strips. Other extremely hard materials when small impressions are required. B | Steei bai | 130 0 70 700 [Al mild and 46" dia medium carbon steels sheet steel and soft steel bare. | Diamond [~~ 100 740 10 750 [Hardened steels cone hardened and tempered steel, alloy steels materials harder | than D 1009. J ‘cosncsie 4iteAls@the Brinell Hardness Number oan be computed from the Rockwell B numbers as follows -. He o= E-e E for scale B= 130 e© = E-Hr = 130-Hp penetration = (130 - Ha) x 0.002 mm if we apply load (P - p) in the Brinell Test, the penetration would be ena cP He Hehe Where H; is the depth of penetration with load P and p respectively equating (i) & (ii) P-p D.BHN (130 - Ry) x 0.002 From which Brinell Hardness no could be found out.BHN Knowing BHN, Tensile Strength of material can be compared from table. Procedure 1. Select eutable major load and Indentor keep the nad on the hook and indentor in position. 2. Place the specimen over the table and raise by rotating the hand-wheel until contact is made with the smail indicator on the dial indicate & S & T and the big needle is nearly vertical. Then rotate the dial until the set position (C 0 or B ~ 30 position) coincides with the main indicator: 3. Apply the major load by moving the handle. Due to the dashpot the major load takes 4 to 5 seconds to act fully on the specimen. Keep the load on 12 to 16 sec. which Is constant in all similar cases ([.e., until the pointer ceases fast movement ‘and continue to creep slightty). J 4. Release the major load by pulling the handle. The dial now gives the required number. Adding the proper prefix according to the load and indentor get the hardiness no. of the material. i 5. \Release the minor load by rotating the handle wheel anti clockwise. Observations 4. Type ‘a. Principle used b...Penetrator used ¢. Loads used 3. Penetration measuring device 2, Capacity 3. = 7 fal Toad | Inden- | Hardness | Equivalent | Remarks SN Matera aoe Prefixtor No. hardness 1 ) ci) sai) 2. 0} (ii) (ii) 3. (i) a | 4 Results, 5 Gonclusions regarding the material used Precautions Sources of Errors‘Questions Why | measured. PNM aAwN number obtained? © |. When and where this is performed? What are the other devices to determine the hardness of the material dial? minor load applied before setting the Rockwell depth measuring dial? Define hardness of a metal and state the various principles on which hardness is ‘What does indicate the hardness number of a material? What is the function of dashpot in the Rockwell Hardness Testing machine? Why a number scales are used in Rockwell Hardness Testing? What is the principle of Vickers hardness test? ‘What is the effect of the duration of the application of major load on the hardness 10. Establish the relation between Rockwell and Brinell Hardnese Numbers. Diagram ness Test Chart for Selecting Load and Penetrators Stale Penetrator | Symbol A Total Load Material for which scale is used Diamond Cone 60kg -| Thin hardened steel strip. Other hard materials when small impression is Tequired. B ‘Steel Ball ANG dia 100 kg All mild and medium carbon teel and soft steel bars. c Diamond Cone 150 kg Hardened steels hardened and toughened high steel, Alloy steels, material harder than mild steel, D~ | Diamond Cone | 700 kg ‘Case hardened steel when a lighter impression is required 150 kg is advisable. = 118" ball 100 kg Cast iron, Aluminum and Magnesium Alloys. F 1/16" ball 60 kg ‘Annealed brass and copper and for thin sheets.