MT Lab Manual ME2091

Laboratory Manual
School of Mechanical Engineering

Material Testing
Laboratory Manual
School of Mechanical Engineering
MATERIAL TESTING
LAB
Kalinga Institute of Industrial Technology

Deemed To Be University
Bhubaneswar-751024
LABORATORY PRACTICE
I HEAR, I FORGET
I SEE, I REMEMBER
I DO, I UNDERSTAND
A PRACTICAL APPROACH IS PROBABLY THE BEST

APPROACH TO GAIN A CLEAR INSIGHT
CODE OF CONDUCT FOR THE LABORATORIES
 All students must observe the Dress Code while in the laboratory.
 Sandals or open-toed shoes are NOT allowed.
 Foods, drinks and smoking are NOT allowed.
 All bags must be left at the indicated place.
 The lab timetable must be strictly followed.
 Be PUNCTUAL for your laboratory session.
 An experiment must be completed within the given time.
 Noise must be kept to a minimum.
 The workspace must be kept clean and tidy at all times.
 Handle all apparatus with care.
 All students are liable for any damage to equipment due to their own negligence.
 All equipment, apparatus, tools and components must be RETURNED to their original
place after use.
 Students are strictly PROHIBITED from taking out any items from the laboratory.
 Students are NOT allowed to work alone in the laboratory without the Lab Supervisor.
 Students are strictly PROHIBITED to bring the data collecting devices such as pen
drive and hard disk etc. Data will only be given by the compact disc.
 Report immediately to the Lab Supervisor if any injury occurs.
 Report immediately to the Lab Supervisor any damages to the equipment.
BEFORE LEAVING THE LAB
 Turn off the power to all equipment.
 Turn off the main power switch to the lab bench.
 Please check the laboratory notice board regularly for updates.

GENERAL INSTRUCTIONS
 You should be punctual for your laboratory session and should not leave the lab
without the permission of the teacher.
 Each student is expected to have his/her own lab book where they will take notes on
the experiments as they are completed.
 The lab books will be checked at the end of each lab session. Lab notes are a primary
source from which you will write your lab reports.
 You and your batch mates will work closely on the experiments together. One partner
doing all the work will not be tolerated. All the batch mates should be able to explain
the purpose of the experiment and the underlying concepts.
 If any equipment is faulty, kindly report immediately to the staff members or

laboratory in charge present in the lab.
ORGANIZATION OF THE LABORATORY
 The experiments must be done according to the timetable and completed within the
scheduled time.
 You should complete the pre-lab work in advance and utilize the laboratory time for
verification only.
 These exercises aim to develop your ability to understand, analyze and test them in the
laboratory.
 A member of staff and a technical assistant will be available during scheduled

laboratory sessions to assist.
 Always attempt experiments, first without seeking help. When you get into difficulty,
ask for assistance.
LAB REPORTS
 Note that, although students are encouraged to collaborate during lab, each must
individually prepare a report and submit it.
 They must be organized, neat and legible.
 Your report should be complete, thorough, understandable and literate.
 You should include a well-drawn and labeled engineering schematic for each
experiment conducted.
 Your reports should follow the prescribed format, to give your report structure and to
make sure that you address all of the important points.
 Graphics requiring- drawn straight lines should be done with a straight edge. Well-
drawn freehand sketches are permissible for schematics.
 Space must be provided in the flow of your discussion for any tables or figures. Do not
collect figures and drawings in a single appendix at the end of the report.
 Reports should be submitted within one week after completing a scheduled lab session.
PRESENTATION
 Experimental facts should always be given in the past tense.
 Discussions or remarks about the presentation of data should mainly be in the present
tense.
 Discussion of results can be in both the present and past tenses, shifting back and forth
from experimental facts to the presentation.
 Any specific conclusions or deductions should be expressed in the past tense.

REPORT FORMAT
Lab write-ups should consist of the following sections:
 Aim of the Experiment: A concise statement describing the experiment and the
results. This is usually not more than 3 sentences. Since the abstract is a summary of
what you have done, it’s a good idea to write this last.
 Equipment used/Apparatus and/or Materials Required: Describe what equipment
and components you used to conduct the experiment
 Theory: Several paragraphs explain the motivation of the experiment. Usually, in this
statement, you state what you intend to accomplish as well as the expected results of
the experiment.
 Procedure: Describe how you conducted the experiment
 Results and Analysis: This is the main body of the report. Observation tables,
schematics, and diagrams should all be included and explained. Results of any
calculations should be explained and shown. State the results of the experiment.
Include any problems encountered.
 Conclusion: Explain how the experiment went, and whether you were able to achieve
the expected results stated in the introduction.
 Precaution: Safety measures should be highlighted.
 Discussion: Scope and practical application.

SAFETY & PRECAUTIONS
 Responsibly conduct yourself at all times in the Laboratory.
 Follow all written and verbal instructions carefully.
 Never work alone in the Laboratory. Work always in the presence of the teacher.
 Do not touch any machine or other accessories until you are instructed to do so.
 Perform only those experiments assigned by your teacher.
 Be alert always and if unsafe conditions are observed bring them to notice
immediately.
 Keep your body parts away from Chemicals or Laboratory equipment.
 Do not wander around, distract, startle or interfere with others’ experiments.
 Aware of the locations and operating procedures of all safety equipment available.
 Dress properly during a laboratory activity. Long hair, dangling jewellery and loose or
baggy clothing are a hazard in the laboratory. Long hair must be tied back, and
dangling jewellery and baggy clothing must be secured. Shoes must completely cover
the foot. No sandals are allowed within the laboratory.

INDEX
Sl. No. Name of the Experiment Page Date of Remarks Signature of

No. Experiment Faculty with
date
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Mark Distribution
MARKS MARKS
Sl. No. TOPIC
ALLOTTED SECURED
1 Daily performance 10
2 Preparedness for the conduct of experiments 20
3 Initiative to learn & interact 10
Presentation of laboratory report

4 20
and regularity in submission
Total of Internal Marks 60
1 Lab exam performance 20
2 Quiz 10
3 Viva-voce 10
Total of External Marks 40
TOTAL MARKS 100
Signature of the Faculty

LIST OF EXPERIMENTS
Sl. No. NAME OF THE EXPERIMENT Page No.
1. Determination of the tensile strength of a mild steel specimen using

UTM.
2. Determination of the compression strength of a mild steel specimen
using UTM
3. Determination of the flexural strength of a mild steel specimen by
three-point bending test using UTM
4. Determination of the impact strength of mild steel by the Izod test
method.
5. Determination of the impact strength of mild steel by Charpy test

method
6. Determination of the hardness of the given specimen by Rockwell
hardness tester.
7. Determination of the hardness of the given specimen by Vickers

hardness tester.
8. Characterization of microstructures of an alloy using a Metallurgical

microscope (light optical microscopy)
9.
10.
Sl. No.: 1 EXPERIMENT No.:.......
TITLE: Tensile test of Mild steel
AIM OF THE EXPERIMENT:
To study the mechanical properties of Mild Steel specimen (ASTM E8) under tension load by
using Universal Testing Machine
SCOPE: To conduct the tensile test of a given mild steel specimen and determination of
following mechanical properties: (i)Limit of proportionality,(ii) Elastic limit, (iii)Yield
strength, (iv) Ultimate tensile strength, (v) Modulus of elasticity(Young’s Modulus), (vi)
Percentage of Elongation, (vi)Percentage of reduction in area
EQUIPMENT/APPARATUS AND/OR MATERIALS REQUIRED:
1. Universal testing machine (UTM)

2. Mild steel Specimen ( ASTM E8 standard)
3. Vernier Caliper
4. Scale
5. Graph Paper
DESCRIPTION OF THE EQUIPMENT:
The different parts of the universal testing machine and tensile setup are shown in Figure 1.
The nomenclature of the tensile specimen is described in Figure 2
Fig. 1. Different parts of UTM (Universal Testing Machine)
1
Fig. 2. Schematic Diagram of the tensile specimen
THEORY:
The tensile test is the most applied one, of all the mechanical tests. For the safe design of
structural components in various engineering applications, the mechanical properties of
materials based on tensile loading conditions should be analyzed. Experiments on tensile tests
can be used to predict the tensile properties and they are conducted by application of axial or
longitudinal forces to a specimen with known dimensions.
STRESS-STRAIN GRAPH
Figure2. The tensile stress-strain graph and different leveling to estimate various mechanical
properties from the curve
The stress-strain graph (Figure 2) is divided into four areas in which the first section
represents elastic deformation and in the remaining areas, only plastic deformation will take
place. However, the material behaves differently in each phase of plastic deformation. Area B
2
defines the flow region where the material is stressed beyond its elastic capability and within
the flow region, the stress changes with increasing strain. In section C the stress increase
sharply and the plastic deformation also increases. At the maximum load, the material's cross-
section begins to reduce in size and ultimately failure occurs.
Elastic deformation (A)
The first phase of the stress-strain damage is elastic deformation. When the stress acting
on the material is removed the material regains its original length. This is called complete
recovery or resilience. Again the area of elastic deformation is divided into two phases. In the
first phase, the material stretches proportionally to the stress acting on it. This extension is
also called linear-elastic or proportional deformation. The point at which the linear-elastic
elongation is maximum is called the proportional limit. Beyond this limit elastic deformation
still takes place, however greater elongation occurs in this section under increasing applied
force. Therefore the elongation or strain is greater than the increasing stress.
The flow region (B)
A further small increase in stress can be enough to cause the proportional limit to be
exceeded. The highest flow point is the point accompanied by an initial sudden loss of quality.
As a result, the stress required to continue to elongate the material reduces immediately and
reaches the lowest flow point.
After these points are exceeded even if the forces are removed immediately the material
does not regain its original properties. When the stress is increased again the dislocations start
to move and increase, which leads to further quality losses at the first flow point, stress and
strain behave irregularly with each other.
Material hardening (C)
If the stress is increased further an increasing number of upright dislocations form in the
crystal lattice preventing the movement of the previous still sliding dislocations. At the same
time, the stress in the crystal lattice continues to increase which causes the hardening of the
material. Here the metal becomes stronger as the strain increases. Hence, it is called "Strain
Hardening". However, this process cannot be continued infinitely. Each material has its
specific maximum force.
Necking (D)
If the maximum force is exceeded the material begins to neck. In the crystal lattice of
the metal bar, so many dislocations have occurred that they can no longer lead to hardening
but instead contribute to the formation of voids or cavities. Apart from necking, the voids
also cause the material cross-section to reduce. The stress now acts on an increasingly smaller
cross-section which enhances this process still further. As the tensile test continues the
necking increases until the tapered cross-section can no longer withstand the stress. This is
when the metal bar tears at the weakest point. Finally, the specimen will have an increase in
length and a reduction in cross-sectional area.
Percentage elongation: Increase in the gauge length of the test piece at maximum force,
expressed as a percentage of the original gauge length
Percentage reduction in the area: Maximum change in the cross-sectional area that has
occurred at the neck during the test expressed as a percentage of the original cross-sectional
area.
3
Tensile strength: Stress corresponding to the maximum force.
Yield strength: When the metallic material exhibits a yield phenomenon, a point is reached
during the test at which plastic deformation occurs without any increase in force.
Modulus of elasticity: It is the slope of the initial linear portion of the stress strain curve.
PROCEDURE:
1. Measure the original length and diameter of the specimen using Vernier Caliper. The
length may either be the length of the gauge section which is marked on the specimen with a
preset punch or the total length of the specimen
2. Switch on the machine and insert the specimen into the grips of the test machine and attach
the strain measuring device (extensometer) to it
3. Start applying the load on the specimen and record the extensometer reading variation with
the load.
4. View the load vs displacement plot and continue the test up to the failure (fracture)
5. Join the pieces of the specimen to join it to measure the change in diameter
6. Join the two specimens to measure the change in specimen length.
7. Do the necessary calculations to estimate other tensile properties
OBSERVATION TABLE(S):
SL no Original Dimensions Final Dimensions
Length Diameter Area (mm2) Length (mm) Diameter Area (mm2)

(mm) (mm) (mm)
1
Avg.
Stress and Strain calculation at any point in the load-displacement curve
SL. No. Load(N) Original Extension Stress Strain

Gauge length (mm)
( Load/ Area) ( Change in length/
Original gauge
length)
4
CALCULATIONS:
Load at limit of proportionality

(i) Limit of proportion = ............N/ m
Original area of cross-section
Load at elastic limit
(ii) Elastic limit = ..............N/mm 2
Yield load
(iii) Yield strength = ............N/mm 2
Maximum tensile load
(iv) Ultimate strength = ............N/mm 2
Stress below proportionality limit
(v) Youngs modulus, E =  .........N/mm 2
Corresponding strain
Final length (at fracture)-original leng th
(vi) Perecentage elongation = ........... .%
Original length
CONCLUSION:
PRECAUTIONS:
1. The alignment of the specimen within the two grips should be proper.
2. The strain measuring device (extensometer) should be removed before the necking
begins
3. Measure the deflection on the scale carefully and accurately
5
DISCUSSION QUESTIONS:
1. What do you mean by YS and UTS? What is their significance?
2. What are the different mechanical properties of the material that can be quantified from the
tensile test?
3. Why load or force is represented on Y-axis and Displacement on the X-axis of Load-
displacement curve?
(Signature of the student)
NAME:...................................................................
ROLL NO.:............................................................
BRANCH:................................SECTION:............
GROUP:.......................SESSION:........................
6
Space for Rough work
7
8
TITLE: Compression test of Mild steel
To study the behavior of the given material (ASTM E9) under Compressive load and to
determine the following: (i) Modulus of elasticity,(ii) Maximum Compressive strength or
ultimate stress (iii) Percentage Decrease in length (iv)Percentage Increase in area
(i) Universal Testing Machine (UTM)
(ii) Mild steel specimen
(iii) Scale
(iv) Vernier Caliper
(v) Graph Paper
THEORY:
The compression test is just the opposite in nature of the tensile test. The nature of
deformation and fracture is quite different from that of the tensile test. Compressive load
tends to squeeze the specimen. Brittle materials are generally weak in tension but strong in
compression. Hence this test is normally performed on cast iron, cement concrete, etc. But
ductile materials like aluminum and mild steel which are strong in tension are also tested in
compression.
However, certain practical difficulties may induce errors in this test.
They are:
• Difficulty in applying truly axial load.
• There is always a tendency of the specimen to bend in addition to Contraction.
To avoid these above errors, usually, the specimen for this test shall be short in length (Not
more than 2 times the diameter). Several m/c and structure components such as columns and
struts are subjected to compressive load in applications. These components are made of high
9
compressive strength materials. Not all the materials are strong in compression. Several
materials, which are good in tension, are poor in compression or vice versa. Cast iron is one
such example. That is why determining ultimate compressive strength is essential before
using a material. This strength is determined by the conduct of a compression test.
Fig.1. The UTM and compression setup
GRAPH:
In a compression test, the stress-strain curve is drawn up to the elastic limit of proportionality.
Metals have approximately the same modulus of elasticity as in the tension test. The curve,
for ductile materials, continues almost without limit as there is no fracture of the material due
to its ductility and the cross-sectional area increases continuously with an increase in load.
The specimen will shorten and bulge out. The compression test is mainly used for testing
brittle materials such as cast iron, concrete, etc. Brittle materials commonly fail along a
diagonal plane due to shearing.
10
(i) Failure pattern during compression
(ii) Load-Displacement curve during the compression test
PROCEDURE:
1. Dimension of the test piece is measured at three different places along with its
height/length by Vernier Caliper and to determine the average cross-section area.
2. Ends of the specimen should be plane. For that, the ends are tested on a bearing plate.
3. The specimen is placed centrally between the two compressions plates, such that the center
of the moving head is vertically above the center of the specimen.
4. Before testing, all valves should be closed condition.
5. Switch on the power supply to the unit and Load is applied to the specimen by opening the
pressure-creating valve and the other valve is closed during testing.
5. The load and corresponding contraction are measured at different intervals from the Digital
Display Unit.
11
6. Load is applied until the specimen fails.
SL. Material type Load(N) Original Original Stress Strain

Area length
No. (Ductile/Brittle) ( Load/ ( Change in
Area) length/
Original
length)
CALCULATION:
Load,P
Stress =  ........N/mm 2
Area,A
Change in length,  l
Strain =  ........
Area,l
Stress
Young's modulus =  ........N/mm 2(Obtained f rom graph)
Strain
(Li -L f )
%Decrease in length = 100  ........%
Li
(A f -A i )
%Increase in are a = 100  ........%
Ai
Ultimate load, Pu
Ultimate compressive strength = ×100=.... ... N/mm 2
Initial area, A i
CONCLUSION:
PRECAUTIONS:
 The specimen should be prepared in proper dimensions.

 The specimen should be properly aligned between the compression plates.
 Take reading carefully.
 After the specimen fails stop the m/c properly
12
I. Compression tests are generally performed on brittle materials-why?
II. How do ductile and brittle materials behave during compression tests?
III. Between tensile test and compression test of brittle material, in which case the strength
will be higher and why?
NAME:...................................................................
ROLL NO.:............................................................
BRANCH:................................SECTION:............
GROUP:.......................SESSION:........................
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14
15
TITLE: Three-point bending test of mild steel
To determine the bending strength and flexural modulus of a specimen (ASTM E290-14)
APPARATUS AND/OR MATERIALS REQUIRED:
1. UTM or Beam apparatus
2. Bending fixture
3. Vernier caliper
4. Meter rod
5. Test piece
DESCRIPTION OF THE APPARATUS:
(i) UTM with three-point bending attachment
(ii) Schematic representation of three-point bending test
16
THEORY
If the beam is supported at the two ends, the beam is known simply supported beam. When a
beam is subjected to load the beam goes under deformation. The difference between the
elastic curve to the original position of the beam is called deflection. When a simply
supported beam is subjected to point load at the midpoint, the beam bends upwards.
The deflection at the mid-point is given by
δ = WL3 / 48EI
Bending strain
17
AB = CD = R θ and A’B’ = (R-y) θ
Strain = ΔL/ L = (A’B’- AB )/ AB = [(R-y) θ – R. θ]/ Rθ = -y/ R
σF = stress, σt = 8PL/ πd3, ε= -6Dd/L2
Bending stress, σ = E. ε and σ = -E.y/R
E = WL3/ 48 δ I
Where W = Load acting at the center, N
L = Length of the beam between the supports (mm)
E = Young’s modulus of the material of the beam, N/mm2
I = the Second moment of area of the cross-section (i.e. moment of Intertia) of the beam,
about the neutral axis, mm4
I = bd3/ 12 = 1/12 ML for rectangular beam
Where b = width of the beam and d = depth of the beam
δ= Deflection
I= π.d4/ 64 for circular section where, d = diameter of the beam
Bending Stress
When the stress is produced due to a bending moment, the stress is known as bending stress.
The bending stress can be obtained by the bending equation
E/R = M/I = σb/y

E = Young’s modullous of material of beam, N/mm2
R = radius of curvature]
M = bending moment
I = the Second moment of area of the cross-section, mm4
f = Bebding stress, N/mm2
y = distance from N.A., mm
the simply supported beam bending moment is zero supports and maximum at mid-point
when the load is symmetrical
18
PROCEDURE
1. Adjust the supports alone the UTM bed so that they are symmetrical to the bed length.
2. Place the beam on the knife edges on the blocks to project equally beyond each knife
edge. See that the load is applied at the center of the beam.
3. Note the initial reading of the vernier scale.
4. Apply the load and note the reading of the vernier scale.
5. Go on taking reading applying load in steps each time till you have a minimum of six
readings.
6. Find the refection (d) each time by subtracting the initial reading of the vernier scale.
7. Draw a graph h between load W and deflection δ. On the graph choose any two
convenient points and between these points find the corresponding values of W and δ.
8. Calculate Young’s modulus from the graph and the bending stress.
9. Repeat the experiment for various beams
OBSERVATION TABLE (S)
Sl. No. Loads on δ Young’s Bending Bending

Beam modulus moment stress
E = WL3/48 δ I M = WL/4 F =My/I =

Δpl/ π.d3
1.
2.
3.
CONCLUSION
1. The Young’s modulus for steel beam/wooden beam is found to be ___N/mm2

2. The bending stress for steel beam/wooden beam is found to be __N/mm2
19
PRECAUTIONS
1. The test piece should properly touch the fixture.

2. The test piece should be straight.
3. Take reading carefully
4. The elastic limit of the beam should not be exceeded.
Discussion Questions:
1. What is Flexural modulus
2. What is bending stress and what is its significance?
20
3. How bending stress is calculated?
NAME:...................................................................
ROLL NO.:............................................................
BRANCH:................................SECTION:............
GROUP:.......................SESSION:........................
21
22
23
TITLE: Impact test of Mild steel specimen (IZOD)
To determine the impact strength of a specimen by Izod impact test.
1. Impact testing machine AMT-8 (Pendulum Type)
Sl.No Name Izod Test
1) Pendulum drop angle 900

2) The effective weight of the 22.057 kg.
pendulum
3) Impact energy 164 J
4) Least count of energy scale 2J
2. Mild steel specimens (75 mm X 10 mm X 10 mm)
24
THEORY
The test is to determine the behavior of materials when subjected to high rates of (Sudden)
loading, usually bending, tension or torsion. It measures the energy absorbed in breaking the
specimen by a single blow or impact.
A pendulum-type single blow impact test, in which the specimen, usually notched, is
fixed at one end and free at another end. The specimen is broken by a falling pendulum. The
energy absorbed as measured by the subsequent rise of the pendulum is a measure of impact
strength or notch toughness.
Notch: A slot or groove of specified characteristics intentionally cut in a test piece to

concentrate the stress localizing the rupture.
Notch Toughness: The high resistance of the material to fracture under suddenly applied
loads at any Stress raiser such as a notch.
Toughness: The ability of the material to absorb energy and deform plastically before
fracture. It is usually measured by the energy absorbed in a notched impact test like
This test provides qualitative information about the ductile and brittle failure through
energy absorbed during impact.
2
10
28 10
75
Izod test piece (All dimensions are in mm)
PROCEDURE:
1. With the striking hammer (pendulum) in a safe test position, firmly hold the steel specimen
in the impact testing machine's vice in such a way that the notch faces the hammer and is half
inside and half above the top surface of the vice.
2. Fix up the Izod striker.Mount the latching tube of the Izod test on the bearing bracket.
3. Loosen the clamping screw of the support and insert the test specimen. Align the center
line of the notch in the planes of support top by using the setting gauge and clamp the
specimen by clamping the screw. Touch the striker to the test specimen.
4. Lift the pendulum by hand till it gets latched in position and then presses the cycle stark
key once and for releasing the pendulum operate. Release handle lever.
5. For removing the broken specimen, hold the specimen by hand and remove the same after
loosening the clamping screw.
25
OBESERVATIONS:-Sample Calculation
Serial No Material Energy Impact Avg,energy Avg.impact

type absorbed strength(I) absorbed in strength
In Joules(K) J/cm2 joules J/cm2
CALCULATIONS:
Impact strength of the specimen of Obs. (1)

I= ................ J/cm2

I= = .................... J/cm2
Average Impact Strength of Mild steel specimen =.................. J/cm2
CONCLUSION: - The energy absorbed for Mild Steel is found out to be (K) are ……..
Joules and the impact strength of mild steel specimen is ……………. J/cm2.
PRECAUTIONS:-
1. Measure the dimensions of the specimen carefully.
2. Hold the specimen (Izod test) firmly.
3. Note down readings carefully.
26
1. What do you mean by impact strength of material?
2. What is the importance of impact strength in real engineering applications?
3. How to calculate the impact strength of material
NAME:...................................................................
ROLL NO.:............................................................
BRANCH:................................SECTION:............
GROUP:.......................SESSION:........................
27
28
29
TITLE: Impact test of Mild steel specimen (CHARPY)
To determine the impact strength of a specimen by Charpy impact test.
1. Impact testing machine AMT-8 (Pendulum Type)
Sl.No Name CharpyTest
1) Pendulum drop angle 1400
2) The effective weight of the 20.996kg.

pendulum
3) Impact energy 300J
4) Least count of energy scale 2J
2. Mild steel specimens (55 mm X 10 mm X 10 mm)
30
THEORY
In an impact test, a specially prepared notched specimen is fractured by a single blow from a
heavy hammer and the energy required is a measure of resistance to Impact. Impact load is
produced by swinging an impact weight (hammer) from a height. Release of the weight from
the height swings the weight through the arc of a circle, which strikes the specimen to
fracture at the notch. Here it is interesting to note that the height through which hammer
drops determines the velocity and the height and mass of a hammer combined determine the
energy. The energy used can be measured from the scale given. The difference between
potential energies is fracture energy. In the test machine, this value is indicated by the pointer
on the scale. This energy value is called impact toughness or impact value, which will be
measured, per unit area at the notch.
This test provides qualitative information about the ductile and brittle failure through
energy absorbed during impact.
450
2
10
27.5
55 10
Charpy test specimen (all dimensions are in mm)
PROCEDURE:
1. With the striking hammer (pendulum) in a safe test position, firmly hold the steel specimen
in the impact testing machine's vice in such a way that the notch faces the hammer and is half
inside and half above the top surface of the vice.
2. Fix up the Charpy striker in their respective positions and on supports.

3. Align the center of specimen notch w.r.t.by means of the Charpy setting gauge. Touch the
striker to the test specimen.
4. Lift the pendulum by hand till it gets latched in position and then presses the cycle start
key once and for release the pendulum operates. Release handle lever.
5. Allow the pendulum to swing freely and break the specimen.
6. After rupture, stop the pendulum slowly by operating the brake rod. Read the absorbed
energy and impact strength directly on the DAS panel.
7. Before proceeding to the next test remove the broken pieces of the test piece and latch the
hammer in its position and repeat the procedure.
31
OBESERVATIONS:-
Serial No Material Energy Impact Avg,energy Avg.impact

type absorbed strength(I) absorbed in strength
In Joules(K) J/cm2 joules J/cm2
CALCULATIONS:
I= ...................J/cm2

I= .................. J/cm2
Average Impact Strength of Mild steel specimen =........................... J/cm2
CONCLUSION: - The energy absorbed for Mild Steel is found out to be (K)
are ……………. Joules and the impact strength of mild steel specimen is ………………
J/cm2.
PRECAUTIONS:-
1. Measure the dimensions of the specimen carefully.
2. Hold the specimen (Charpy test) firmly.
3. Note down readings carefully.
32
1. What is the difference between IZOD and CHARPY impact test?
2. How the impact strength of ductile material varies from the impact strength of brittle
material?
3. How the impact strength of the material is related to the hardness of the material?
NAME:...................................................................
ROLL NO.:............................................................
33
BRANCH:................................SECTION:............
GROUP:.......................SESSION:........................
34
35
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TITLE: Rockwell Hardness Test
Measurement of the hardness of mild steel bar using Rockwell hardness test
1. Mild steel bar
2. Rockwell Hardness Tester
Figure 1. Rockwell Hardness Tester
THEORY:
Hardness is defined as the resistance of a material to localized plastic deformation, i.e. a
small dent or a scratch. A sharp (hard) object is used to create a dent/scratch on the material.
The depth of the scratch/dent made is measured and relates to its hardness. In all hardness
tests, a definite force is mechanically applied to the test piece. Common indenters are
generally made of hardened steel or diamond.
Rockwell hardness tester presents a direct reading of hardness number on a dial provided
with the machine. Principally this testing is similar to Brinell hardness testing. It differs only
in diameter and material of the indenter and the applied force. Although many scales are
having different combinations of load and size of indenters but commonly 'C' scale is used
and the hardness is represented as 'HRC' (unit). Here the indenter has a diamond cone at the
tip and the applied force is 150 kgf. Soft materials are often tested on a’B’ scale with a 1.6
mm diameter steel indenter at 60 kgf. The specimen may be a cylinder, cube, or thick or thin
metallic sheet. Figure 1 shows the schematic of the Rockwell testing machine. Figure 2
shows the schematic of the diamond indenter. Table 1 shows the scales used in Rockwell
testing and their respective testing parameters used.
37
Figure 2. Schematic of the diamond indenter showing the working principle.
Table 1. Scales used in Rockwell testing
PROCEDURE:
1. Insert a ball indenter of diameter D in the ball holder of the machine. Depending on the
material type choose the appropriate scale (indenter) from Table1.
2. Clean to specimen surface to make sure it is devoid of any dust, dirt, oil, grease, etc.
3. Align the indenter head on the top of the surface where the test is to be made.
4. Set the minor (initial) load and major load according to the scale chosen from Table 1.
5. Push the test button and wait for the machine to complete the test and give a result. In case
the indentation marks are not clear, the machine will not be able to give automatic results. In
such a case manual measurements then need to be done to show the depth of penetration with
the help of the optical eyepiece provided.
6. For the hardness test, a minimum of five reading need to be taken per specimen. The
distance between the reading should be at least 3 times the diameter of the indenter.
38
Reading Material Scale Total Load Hardness No.
1
2
3
4
5
Avg:
CONCLUSIONS:
Rockwell hardness of given specimen is..................HRA/HRB/HRC.
PRECAUTIONS
While testing the following precautions should be taken:
1. Indentation should not be made nearer to the edge of a specimen to avoid unnecessary
concentration of stresses. In such a case the distance from the edge to the center of
indentation should be greater than 2.5 times the diameter of indentation.
2. The spacing between the two adjacent impressions should be at least 3 times the
diameter of the indentation.
3. The rapid rate of applying load to the specimen should be avoided. The load applied
on the ball may rise a little because of its sudden action, also rapidly applied load will
restrict the plastic flow of a material, which produces an effect on the size of the
indentation.
39
1. Why it is necessary to do a hardness test?
2. Describe the procedure for the Rockwell test, explaining the reason for the pre-load.
3. How you can correlate the hardness numbers with the properties of the materials?
4. What are the precautions to be taken before conducting the experiments?
5. What is the principle involved in the Rockwell hardness test?
NAME:...................................................................
ROLL NO.:............................................................
BRANCH:................................SECTION:............
GROUP:.......................SESSION:........................
40
41
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TITLE: Vicker's Hardness Test
Measurement of the hardness of mild steel bar using Vicker's hardness test
1. Mild steel bar
2. Vicker's Hardness Tester and accessories
Figure 1. Micro-Vicker's hardness tester
THEORY:
Hardness is defined as the resistance of a material to localized plastic deformation, i.e. a

small dent or a scratch. A sharp (hard) object is used to create a dent/scratch on the material.
The depth of the scratch/dent made is measured and relates to its hardness. In all hardness
tests, a definite force is mechanically applied to the test piece. Common indenters are
generally made of hardened steel or diamond.
The Vickers hardness test follows the Brinell hardness testing principle. Figure 1 shows the
photograph of the Vicker's hardness testing machine. Here an indenter of definite shape is
43
pressed into the material to be tested for a pre-determined time. The load is removed and the
diagonals of the resulting indentation are measured with the help of a precise microscope.
From these measurements, the hardness number is calculated by dividing the load by the
surface area of indentation.
The indenter here is made of diamond, which is in the form of a square-based pyramid with
an angle of 136  between faces. Figure 2 shows the schematic diagram explaining the
principle. The faces of the diamond indenter are highly polished, and the point is sharp. The
loads applied to vary from 1 to 120 kg; the standard loads are 5, 10, 20, 30, 50, 100, and 120
kg. For most hardness testing, 50 kg is the maximum. The diagonal lengths are measured as
d1 and d2, as shown in Figure 2. The hardness no, HV is given as per Equation 1, where F is
the force applied and A is the cross-sectional area.
(1)
(2)
It simplifies down to,
kgf/mm2 (3)
(4)
where F is in N and d is in mm.
44
Figure 2. Schematic of the working principle for calculation of hardness number.
PROCEDURE:
1. Clean to specimen surface to make sure it is devoid of any dust, dirt, oil, grease, etc.
2. Align the indenter head on the top of the surface where the test is to be made.
3. Set the minor (initial) load and major load according to the material.
4. Push the test button and wait for the machine to complete the test and give a result. In
case the indentation marks are not clear, the machine will not be able to give
automatic results. In such a case manual measurements then need to be done to show
the depth of penetration with the help of the optical eyepiece provided.
5. For the hardness test, a minimum of five readings need to be taken per specimen. The
distance between the reading should be at least 3 times the diameter of the indenter.
Type of Load X-diagonal Y-diagonal Average VHN No Average

Material Length Length Length of hardness
X&Y number
diagonal
CONCLUSION:
Vickers hardness Number of the given specimen is......................VHN
PRECAUTIONS
While testing the following precautions should be taken:
1. The test should be carried out on a smooth surface, even, and free from oxide, foreign
matter and lubricants.
2. The thickness of the test piece or the layer under the test shall be at least 1.5 times the
diagonal length of the indentation.
45
3. For test pieces of small cross-section or irregular shape, it may be necessary to
provide some form of additional support.
4. Indentation should not be made nearer to the edge of a specimen to avoid unnecessary
concentration of stresses.
5. The rapid rate of applying load to the specimen should be avoided. The load applied
on the ball may rise a little because of its sudden action, also rapidly applied load will
restrict the plastic flow of a material, which produces an effect on the size of the
indentation.
Answer the following questions for the given list of materials: Mild steel, Cast Iron, Spring
steel, Brass and Aluminum
1. Why should softer materials like Al have a lower hardness number?
2. List the materials with higher hardness. Analyze the results with your knowledge of these
materials:
3. Correlate the structure-properties relationship of the materials, viz
(i) which of the materials have FCC, BCC and HCP structure
(ii) Depending on their structure which material is expected to have higher hardness and why?
NAME:...................................................................
ROLL NO.:............................................................
46
BRANCH:................................SECTION:............
GROUP:.......................SESSION:........................
47
48
TITLE: Metallurgical microscope
Characterization of microstructures of an alloy using a metallurgical microscope (light optical
microscopy)
SCOPE: The optical microscopy reveals the following microstructural features:
1. Surface morphology
2. Grain shape and size
3. Grain boundary
4. Size, Shape and distribution of various phases, inclusions and precipitation,
etc.
1. Metallurgical microscope
2. Properly polished (flat) specimen
DESCRIPTION OF THE EQUIPMENT:
Light optical microscope (LEICA)
49
THEORY:
The microstructure plays a significant role in many important properties of alloys. A

thorough understanding of the relationship between microstructure and alloy properties is the
basic objective of metallography. Metallography is the study of alloy microstructures: size
and shape of grains, grain/ phase boundary, distribution of phases, inclusions and other
constituents. The knowledge from metallography is utilized in the field of metallurgy (alloy
design and development) and alloy production. Varieties of techniques, most often
microscopy are used to study the alloy microstructure. A metallurgical microscope based on
light optical microscopy (LOM) is one of the most common techniques generally used to
reveal the basic microstructure of materials. The basic functions of LOM are illuminating a
specimen and creating a magnified image of the specimen. The important characteristics of
the microscope are (1) magnification, (2) resolution and (3) flatness of field. The resultant
magnification is the product of the magnifying power of the objective and that of the ocular
(eyepiece).
MICROSCOPE PARTS AND FUNCTIONS

1. Eyepiece: The eyepiece (sometimes called the 'ocular') is the lens of the microscope closest
to the eye that you look through. It is half of the magnification equation (eyepiece power
multiplied by objective power equals magnification) and magnifies the image made by the
objective lens, sometimes called the virtual image. Eyepieces come in many different powers.
One can identify which power any given eyepiece is by the inscription on the eyecup of the
lens, such as "10x", "20x", "50x", "100X" etc.
2. Eyepiece Holder: This simply connects the eyepiece to the microscope body, usually with
a setscrew to allow the user to easily change the eyepiece to vary magnifying power.
3. Body: The main structural support of the microscope which connects the lens apparatus to
the base.
4. Nose Piece: This connects the objective lens to the microscope body. With a turret, or
rotating nose piece as many as five objectives can be attached to create different powers of
magnification when rotated into position and used with the existing eyepiece.
50
5. Objective lens: The lens closest to the object being viewed creates a magnified image in
an area called the "primary image plane". This is the other half of the microscope
magnification equation (eyepiece power times objective power equals magnification).
Objective lenses have many designs and qualities which differ with each manufacturer.
Usually inscribed on the barrel of the objective lens are the magnification power and the
numerical aperture (a measure of the limit of resolution of the lens).
6. Focusing Mechanism: Adjustment knobs to allow coarse or fine (hundredths of a

millimeter) variations in the focusing of the stage or objective lens of the microscope.
7. Stage: The platform on which the prepared slide or object to be viewed is placed. A slide
is usually held in place by spring-loaded metal stage clips. More sophisticated high-powered
microscopes have mechanical stages which allow the viewer to smoothly move the stage
along the X (horizontal path) and Y (vertical path) axis. A mechanical stage is a must for
high-power observing.
8. Illumination Source: The means employed to light the object to be viewed. The simplest
is the illuminating mirror which reflects an ambient light source to light the object. Many
microscopes have an electrical light source for easier and more consistent lighting. Generally,
electrical light sources are either tungsten or fluorescent, the fluorescent being preferred
because it operates at a cooler temperature. Most microscopes illuminate from underneath,
through the object, to the objective lens. On the other hand, stereo microscopes use both top
and bottom illumination.
9. Base: The bottom or stand upon which the entire microscope rests or is connected.
10. Photography unit with CMOS or CCD sensor able to make pictures via microscope.
SPECIMEN PREPARATION BEFORE LOM:

Specimen preparation for LOM is very important otherwise the image quality and
observation of microstructural features will significantly get affected. Following basic steps
are needed to be followed while preparing the specimen for LOM. (i)Cutting a specimen into
small pieces (ii) Mounting the specimen for easy holding (iii) Grinding/ mechanical polishing
using different grades of emery papers (iv) diamond paste polishing/ cloth polishing
(v)Etching/ selective chemical attack to reveal the microstructures of the alloy.
51
PROCEDURE
1. The surface of the specimen to be examined optically should be flat and level.
2. The specimen should be placed on the stage of the microscope so that its
surface is perpendicular to the optical axis.
3. Proceed to Microscopic Examination
4. If the specimen has many scratches and marks or the microstructure cannot be
seen after several etches, return to fine grinding and go back through the
necessary steps
5. If the surface of the specimen is neat and clean without having scratches then
measure the various microstructural features: the grain size, boundaries,
phases, etc. according to the requirement of the user.
OBSERVATION(S)
Observing the micrographs at optimal magnification find out the
Specimen type Magnification Surface characteristics Microstructural features

observed
CONCLUSION:
PRECAUTIONS
1. Safety goggles must be worn when using the disc polishers

2. Make sure the specimen and hands have been thoroughly cleaned before Polishing.
3. Do not contaminate the polishing wheel; cover the wheel when it's not in use
4. During etching, the chemicals should be handled with care
5. While putting the samples in an optical microscope make sure the surface should be
flat.
52
1. What is the difference between Resolution and Magnification?
2. How is the magnification of a microscope defined?
3. What is the importance of microstructure? And why microstructure is different for

different materials?
NAME:........................................
ROLL NO.:....................................
BRANCH & SECTION:....................
GROUP: .............. & SESSION:..............
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55
56
K
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Laboratory Manual

School of Mechanical Engineering

Kalinga Institute of Industrial Technology

A PRACTICAL APPROACH IS PROBABLY THE BEST

 Sandals or open-toed shoes are NOT allowed.

 Foods, drinks and smoking are NOT allowed.

 All bags must be left at the indicated place.

 The lab timetable must be strictly followed.

 Be PUNCTUAL for your laboratory session.

 An experiment must be completed within the given time.

 Noise must be kept to a minimum.

 The workspace must be kept clean and tidy at all times.

 Handle all apparatus with care.

 Report immediately to the Lab Supervisor if any injury occurs.

 Report immediately to the Lab Supervisor any damages to the equipment.

BEFORE LEAVING THE LAB

 Turn off the power to all equipment.

 Turn off the main power switch to the lab bench.

 Please check the laboratory notice board regularly for updates.

 If any equipment is faulty, kindly report immediately to the staff members or

 A member of staff and a technical assistant will be available during scheduled

 They must be organized, neat and legible.

 Your report should be complete, thorough, understandable and literate.

 Experimental facts should always be given in the past tense.

 Any specific conclusions or deductions should be expressed in the past tense.

Lab write-ups should consist of the following sections:

 Procedure: Describe how you conducted the experiment

 Precaution: Safety measures should be highlighted.

 Discussion: Scope and practical application.

 Responsibly conduct yourself at all times in the Laboratory.

 Follow all written and verbal instructions carefully.

 Perform only those experiments assigned by your teacher.

 Keep your body parts away from Chemicals or Laboratory equipment.

 Do not wander around, distract, startle or interfere with others’ experiments.

the foot. No sandals are allowed within the laboratory.

Sl. No. Name of the Experiment Page Date of Remarks Signature of

2 Preparedness for the conduct of experiments 20

3 Initiative to learn & interact 10

Presentation of laboratory report

Total of Internal Marks 60

1 Lab exam performance 20

Total of External Marks 40

TOTAL MARKS 100

Signature of the Faculty

Sl. No. NAME OF THE EXPERIMENT Page No.

1. Determination of the tensile strength of a mild steel specimen using

5. Determination of the impact strength of mild steel by Charpy test

7. Determination of the hardness of the given specimen by Vickers

8. Characterization of microstructures of an alloy using a Metallurgical

TITLE: Tensile test of Mild steel

AIM OF THE EXPERIMENT:

EQUIPMENT/APPARATUS AND/OR MATERIALS REQUIRED:

1. Universal testing machine (UTM)

DESCRIPTION OF THE EQUIPMENT:

Fig. 1. Different parts of UTM (Universal Testing Machine)

SL no Original Dimensions Final Dimensions

Length Diameter Area (mm2) Length (mm) Diameter Area (mm2)

Stress and Strain calculation at any point in the load-displacement curve

SL. No. Load(N) Original Extension Stress Strain

Load at limit of proportionality

1. What do you mean by YS and UTS? What is their significance?

(Signature of the student)

TITLE: Compression test of Mild steel

AIM OF THE EXPERIMENT: