3-FDP-63-M-308-MT Lab-Total

STATE BOARD OF TECHNICAL EDUCATION
& TRAINING::AP, VIJAYAWADA
DIPLOMA IN MECHANICAL ENGINEERING

III SEMESTER
MATERIAL TESTING LAB (M-308)
MANUAL (AS PER C-16 CURRICULUM)
LAB SHEETS
LABORATORY SHEET 2.1 TENSION TEST
TENSION TEST
1) Objective: To conduct a tensile test on a mild steel specimen and determine the following:
1. Elastic limit 2. Yield strength 3. Ultimate strength
4. Young’s modulus of elasticity 5. Percentage of elongation 6. Percentage of reduction in area.
2) Apparatus:
1. Universal testing machine (UTM) 2. Mild Steel specimen 3.Vernier caliper

4. Steel rule 5.Extensometer 6.Graph paper
3) Task Analysis:
A) Knowledge:
 UTM
 Vernier calipers
 Stress–strain curve
 Young’s modulus
 Percentage of elongation
 Percentage of reduction in area
 Tensile strength
NITTTR EXTENSION CENTRE-VIJAYAWADA

FIG: UNIVERAL TESTING MACHINE
B) Skill:
Category of Skill Sub Task

 Identifying the components required.
Handling of
 Operating controller for moving jaws
apparatus
 Fixing extensometer.
 Measuring gauge length and diameter.
 Fixing job between UTM jaws by controller.
Manipulation of
 Loading
apparatus
 Hydraulic pump operation
 Fixing job between UTM jaws by controller.

 Rate of loading
 Note down readings of load and extensions from digital
panel board
Precise  Precise operation of pump
Operations/Activities  Calculating Young’s modulus, % of elongation, % of
reduction in area.
 Draw stress-strain curve
4) Teaching Points:
Sl. Time allocation

Teaching point
No (20 mins Suggestive)
1 Required components 5min
2 Job setup 5min
3 Note down readings 3min
4 Hydraulic Pump operation 2 min
5 Sample calculation 5 min
A) Procedural Precautions:
 Fixing the job carefully
 The grips used in testing machine must be properly serrated so that there is no chance of
slippage of specimen (The specimen should be gripped such that the two ends of the specimen are
covered by the grip, approximately 3 mm away from its gage-length. It is important that the
specimens are tightly gripped onto the specimen grips to prevent slipping, which will otherwise
result in experimental errors.)
 Use the “Up” and “Down” buttons, which are located next to the “Return” button to adjust the
position of the upper grip(Make sure that the specimen is vertically aligned, if not a tensional force,
rather than axial force, will result).

 Specifications of the specimen according to the ASTM standards.
 Misalignment of the specimen should not be allowed during the test.
 Take measurements of the specimen accurately.
 Note down the readings carefully.
 Operate the hydraulic valves carefully.
B) Safety Precautions:
 Observe the experiment at a safe distance (about 1.5 meters away), at an angle and take note of the
failure mode when the specimen fails (Be sure to wear safety glasses. Do not come close to
equipment when the tensile test is running).
 Wear shoe and apron.
 Don’t wear loose cloths.
5) Need And Scope:

 By knowing the percentage of elongation, material can be classified as brittle or ductile.
 It measures tensile strength. If your design needs a certain material tensile strength, you will know if
this material will work for you.
 You can get tensile modulus out of the test results. This can go into your design equations to see if the
material will work for you.
 You can get Poisson’s Ration, which is important for use in finite element analysis

6) SCHEME OF EVALUATION:
WEIHTAGE WITH
TOTAL
Category of Skill SUB TASK COMPETENCY LEVEL
(50)
INDIVIDUALLY
A) Identifying the components
required.
1. Handling of B) Operating controller for moving
A B C T 5
apparatus jaws.
1 2 2 5
C) Fixing extensometer.
A) Measuring gauge length and

diameter.
A B C D T
2. Manipulation of B) Fixing job between UTM jaws by
4 5 4 2 15 15
apparatus controller.
C) Loading
D) Hydraulic pump operation
A) Fixing job between UTM jaws by
controller.
B) Rate of loading
C) Note down readings of load and
3. Precise extensions from digital panel board A B C D E F T
Operations/Acti D) Precise operation of pump 4 2 2 2 12 3 25 25
vities E) Calculating Young’s modulus, % of
elongation, % of reduction in area.
F) Draw stress-strain curve
.
A) Co Operation
B) Co- Ordination A B C D E T
4. Values C) Communication 1 1 1 1 1 5 5
D) Sharing
E) Leadership
7) ASSESSMENT QUESTIONS:
1. Identify the components required. (LO)

2. Operate controller for moving jaws (LO)
3. Fix extensometer(LO)
4. Measure gauge length and diameter.(MO)
5. Fix job between UTM jaws by controller(MO)
6. Operate Hydraulic pump (MO)
7. Note down readings of load and extensions from digital panel board (HO)
8. Operate Hydraulic Pump (HO)
9. Calculate Young’s modulus, % of elongation, % of reduction in area(HO)
10. Draw stress-strain curve (HO)
8) VIVA QUESTIOINS:
1) Which steel have tested ?

2) In which direction do you applying load on tension test specimen?
3) How do you measure elongation
4) What kind of fracture has occurred in the tensile specimen and why?
5) What changes to specimen do you observe after fracture?
6) Differentiate between an engineering stress-strain and true stress-strain curve?
7) Draw the schematic diagram of an engineering stress-strain and true stress-strain curve.
8) What do you understand from load vs extension graph?
9) How stress and strain varying with rate of loading
10) Why mild steel material is chosen for tension test?
11) What do you understand when rate of loading increased?
12) Why don’t you conduct tension test on brittle material?
13) Why breaking load is less than peak load (ultimate load)?
14) How you indicate the proportional limit point on stress-strain curve obtained from tension
test?
15) How do you understand hook’s law from this tension test?

LAB SHEET 2.2 COMPRESSION TEST
COMPRESSION TEST
1) Objective: To find the compressive strength of a concrete cube using CTM.

2) Apparatus: CTM, Concrete cube (specimen)
3) Task Analysis
A) Knowledge:
1) Definition of load and Types of loading
2) Types of axial loading
3) Compression Testing Machine (CTM)
4) Stating the specifications of the test specimen as per ASTM/IS standards
5) Load valve
6) Back oil valve
B) Skill
Handling of  Identifying the components required.

apparatus  Measuring the dimensions of a given concrete cube.
 Connecting the power supply and placing the specimen.

Manipulation of
 Operating the load valve and back oil valve.
apparatus
 Observing the rate of loading
Precise  Checking of both the valves in closed position before start of the
Operations experiment.
Activities  Operating the load valve.
 Observing the readings and noting of the final reading.
NITTTR EXTENSION CENTRE, VIJAYAWADA

4) Teaching Points:
Sl. Time allocation

Teaching point
1 Components of CTM 5 min
2 Working of CTM 4 min
3 Operation of load valve 3 min
4 Specimen details 3 min
5 Need and scope of the experiment 3 min
6 Safety Precautions 3 min
a) Procedural precautions :
 Observe the valve opening and closing carefully
 Check that both the valves are closed before start of the experiment.
 The specimen must be kept at the centre of cross-head so that a uniform compressive
loading can be assured on the specimen.
 The loading is to be increased gradually.
 The size of the specimen is to be measured accurately.
b) Safety Precautions :
 All loose clothing must be tucked in.

 Safety boots or enclosed shoes must be worn.
 Always wear an apron.
5) Need And Scope:

The goal of a compression test is to determine the behavior or response of a material while it
experiences a compressive load by measuring fundamental variables such as stress, strain and
deformation.
Compression tests are performed on brittle materials as these materials fail in shear. It is seen
that the shear develops along a diagonal plane which is maximum on a plane inclined at 45° from the
direction of compression load. In compression loading, the fracture of the specimen takes place due to
bulging action. The property of a material to bulge under compressive loading is called malleability. It is
the ductility that is associated with tensile loading while it is malleability that is associated with
compressive loading.
The maximum load capacity of the CTM used is 2000KN. Students for research can work to
construct a CTM with increased load capacity.

6) Planning And Organisation :
ACTION ACTIVITY
Check for 1. The specimen must be kept at the centre of lower fixed jaw so that a
uniform compressive loading can be assured on the specimen.
2. The loading is to be increased gradually.
3. The size of the specimen is to be measured accurately
For design and Read the teaching points carefully.
instruction
7) Scheme Of Evaluation:
WEIHTAGE WITH
TOTAL
(50)
INDIVIDUALLY
A) Identifying the components required.
1. Handling of B) Measuring the dimensions of a given
A B T 5
apparatus concrete cube.
3 2 5
A) Connecting the power supply and
placing the specimen. A B C T
2. Manipulation
B) Operating the load valve and back oil 6 4 5 15 15
of apparatus valve.
C) Observing the rate of loading
A) Checking of both the valves in closed
position before start of the A B C T
3. Precise
experiment.
Operations 5 10 10 25 25
B) Operating the load valve.
Activities C) Observing the readings and noting of
the final reading.
A) Co Operation
B) Co- Ordination
4. Values C) Communication 5 5
D) Sharing
E) Leadership
8) Assessment Questions:
1. Identify the components required.(LO)

2. Measure the dimensions of a given concrete cube. (LO)
3. Connect the power supply and placing the specimen. (MO)
4. Operate the load valve and back oil valve. (MO)
5. Observe the rate of loading.(MO)
6. Check of both the valves in closed position before start of the experiment. (HO)
7. Operate the load valve. (HO)
8. Observe the readings and noting of the final reading. (HO)

9) Viva Questions
1. What is the purpose of compression test?

2. How do you calculate compressive stress?
3. Why compressive strength important?
4. What is the significance of ultimate compressive strength?
5. How is compression test different from tensile test?
6. Why is compressive test conducted on brittle materials?
7. What is the main failure effect arising during the compression test?
8. Is steel stronger in compression or tension?
9. Why is concrete stronger in compression than in tension?
10. What is factor of safety?
11. What is ultimate strength?
12. What are the different types of stresses?

LABORATORY SHEET 2.3 SHEAR TEST
SHEAR TEST
1) Objective:
 To determine the maximum shear strength of the given bar by conducting shear test on UTM.
2) Apparatus:
 Universal Testing machine (UTM)
 Mild steel specimen
 Shear test attachment
 Veriner caliper
3) Task Analysis
A). Knowledge:
1) UTM (Universal Testing machine)

2) Specimen
3) Shear attachments
4) Remote for operating movement of the jaws
B) Skill:
Handling of ● Identifying the components required.

apparatus ● Identifying the specifications of the specimen
● Checking the power supply and working of UTM remote.

Manipulation of
● Checking start and stop buttons, Opening and closing valves.
apparatus
● Checking the position of specimen in shear attachment
● Measuring the diameter of the specimen and fixing the Specimen in

the Shear attachment.
Precise Operations
● Keeping the shear equipment on the fixed jaw of UTM and apply the
Activities
load slowly at right angles to the axis of piece through the central
block and noting of load at fracture.
NITTTR EXTENSION CENTRE, VIJAYAWADA (ECV)

4) Teaching Points:
Time allocation
Sl. No Teaching point
(20 mins Suggestive)
1 Construction and working of UTM 6 min
2 Operation of upper jaw and lower jaw with remote 3 min
3 Calculation of shear strength of the given specimen 5 min
5 Precautions 2 min
Total 20 min
A) Procedural Precautions:
1) The measuring range should not be changed at any stage during the test.
2) Inner diameter of the hole in the shear attachment should be slightly greater than that of
the specimen.
3) Measure the diameter of the specimen accurately.
4) Care should be taken while applying the loads on the UTM.
5) After shearing specimen stops the machine.
B) Safety Precautions:
1)
2) Observe the experiment at a safe distance (about 1.5 meters away), at an angle and take
note of the failure mode when the specimen fails (Be sure to wear safety glasses. Do not
come close to equipment when the tensile test is running).
3) Wear shoe and apron.
4) Don’t wear loose cloths.
5) Need And Scope Of The Experiment:
Place the shear test attachment on the lower table, this attachment consists of cutter.
The specimen is inserted in the shear test attachment & lift the lower table so that the zero is adjusted,
then apply the load such that the specimen breaks in two or three pieces. If the specimen breaks in two
pieces, then it will be single shear & if it breaks in three pieces, then it will be in double shear.

WEIHTAGE WITH
TOTAL
(50)
INDIVIDUALLY
1. Handling of B) Identifying the specifications of the
A B T 5
apparatus specimen
3 2 5
A) Checking the power supply and working of
UTM remote
2. Manipulatio B) Checking start and stop buttons ,Opening
A B C T
n of and closing valves. 20
apparatus C) Checking the position of specimen in 3 7 10 20
shear attachment
A) Measuring the diameter of the specimen

and fixing the Specimen in the Shear
attachment.
3. Precise
B) Keeping the shear equipment on the fixed A B T
Operations 20
jaw of UTM and apply the load slowly at 10 10 20
Activities
right angles to the axis of piece through
the central block and noting of load at
fracture.
A) Co Operation
B) Co- Ordination
4. Values C) Communication 5
D) Sharing 5
E) Leadership
1. Identify the components required. (LO)

2. Identify the specifications of the Specimen (LO)
3. Check the power supply and working of UTM remote(MO)
4. Check start and stop buttons, Opening and closing valves(MO).
5. Check the position of specimen in shear attachment(MO)
6. Measure the diameter of the specimen and fixing the Specimen in the Shear attachment.(MO)
7. Keeping the shear equipment on the fixed jaw of UTM and apply the load slowly at right angles
to the axis of piece through the central block and noting of load at fracture.(MO)

8) VIVA QUESTIONS:
1. Distinguish between single shear and double shear?
2. Distinguish between average shear stress and maximum shear stress?
3. Why Modulus of rigidity is not determined from shear test?
4. Why structural component is designed mainly by considering double shear strength?

5. What is twisting moment?
6. Does the shear failure in wood occur along the 45° shear plane?
7. How deformation calculated?
8. What is unit of shear strength?

LAB SHEET 2.4 IMPACT TEST (IZOD and CHARPY)
IMPACT TEST (IZOD and CHARPY)
1) Objective:
To determine impact strength (Toughness) of mild steel specimen by impact test.
2) Apparatus:
1.Imapct testing machine
2. A mild steel standard test specimen.
3) Task Analysis
A) Knowledge:
1) Components of Impact testing machine.
2) Working of Impact testing machine.
3) Basic Mechanical properties of materials.
4) Working of vernier calipers and vernier bevel protractor
5) Precautions and safety procedures.
B) Skill:
i) Izod Impact Test
● Identifying the parts of Izod testing equipment.

Handling of
● Using of allen key to fix striking hammer.
apparatus
● Fixing Izod striker to striking hammer.
● Fixing the one end of test specimen in jaws.

Manipulation of
● Adjusting the striking hammer at 900 to test specimen and lock it.
apparatus
● Adjusting the dial needle to extreme position.
● Preparing the specimen with 450 notch.

● Recording the dial reading after releasing the hammer without test
Precise Operations specimen.
Activities ● Recording the dial reading after releasing the hammer with test
specimen.

ii). Charpy Impact Test
● Identifying the components required.

Handling of
● Using of allen key to fix striking hammer.
apparatus
● Fixing charpy striker to striking hammer.
● Fixing the two end of test specimen in jaws.

Manipulation of
● Adjusting the striking hammer at 1350 to test specimen and lock it.
apparatus
● Adjusting the dial needle to extreme position.
● Preparing the specimen with 450 notch.

● Recording the dial reading after releasing the hammer without test
specimen.
Precise Operations
● Recording the dial reading after releasing the hammer with test
Activities
specimen.
4) Teaching points (IZOD and CHARPY IMPACT TEST):
Sl. Time allocation

Teaching point
Construction and working of Impact
1 6 min
Testing Machine
Specifications of Impact testing
2 6 min
machine
Definition of Impact
3 3 min
strength(Toughness)
Calculation of impact energy and
4 3 min
Impact Strength
A) Procedural Precautions (Izod And Charpy Impact Test):

1) Note down the Readings without parallax error.
2) Measure the dimensions of the specimen carefully.
3) Apply brakes on the striking hammer only in the forward motion.
B) Safety Precautions(Izod And Charpy Impact Test):

1) Laboratory personnel should not stand in the direction of movement of striking hammer.
2) Beware of loose clothing while operating.
3) Fixing the specimen firmly.

5) NEED AND SCOPE OF THE EXPERIMENT (IZOD and CHARPY IMPACT TEST):
Impact Test is used for determining the amount of forces that are absorbed by materials
when it reaches the point of fracture. This amount of energy gives the analysis of the notch
hardness of material.
 In forging industry, the test can be used to determine the malleability and ductility of a material that is
being forged.
 In the rubber industry, this test is used for determining the shock absorbing ability of a type of rubber
so that its proper application could be decided.
 In plastic industry, this test is used for analyzing the breaking strength of a sample when it is subjected
to a high impact from a pendulum. This helps in ensuring that the material is best for an application
where it is subjected to such impacts.
6) SCHEME OF EVALUATION (IZOD and CHARPY IMPACT TEST):
WEIHTAGE WITH
TOTAL
(50)
INDIVIDUALLY
A. Identifying the components required.

1.Handling of B. Using of allen key to fix striking
A B C T 5
apparatus hammer.
2 1 2 5
C. Fixing striker to striking hammer
A. Fixing the one end of test specimen in jaws.

2.Manipulation of B .Adjusting the striking hammer to test A B C T
15
apparatus specimen and lock it. 4 4 7 15
C. Adjusting the dial needle to extreme position.
A. Preparing the specimen with 450 notch

B. Recording the dial reading after releasing the
hammer without test specimen.
3.Precise Operations A B C T
C. Recording the dial reading after releasing the 25
Activities 7 9 9 25
hammer with test specimen.
A) Co Operation
B) Co- Ordination
4.Values C) Communication 5
D) Sharing 5
E) Leadership

7) ASSESSMENT QUESTIONS (IZOD and CHARPY IMPACT TEST):
1. Identify the components required.(LO)

2. Use of Allen key to fix striking hammer.(LO)
3. Fix the one end of test specimen in jaws.(MO)
4. Adjust the striking hammer to test specimen and lock it.(MO)
5. Adjust the dial needle to extreme position.(MO)
6. Prepare the specimen with 450 notch(HO)
7. Record the dial reading after releasing the hammer without test specimen.(HO)
8. Record the dial reading after releasing the hammer with test specimen.(HO)
8) VIVA QUESTIONS
1. How does an Izod Impact Test works?

2. How does Charpy Impact Test works?
3. How does the impact test significant in practice?
4. Differentiate between Izod and charpy impact test?
5. Which type of material used in impact test?
6. What is angle of notch in the test specimen for impact test?
7. What is initial position of the striking hammer for izod test?
8. How specimen is positioned in Izod impact test?
9. How specimen is positioned in Charpy impact test?

LABORATORY SHEET 2.5 (A) BRINELL’S HARDNESS TEST
BRINELL’S HARDNESS TEST
1) Objective: To determine the hardness number of the given specimen by using Brinell’s Hardness
Tester.
2) Apparatus: Brinell’s hardness tester, micrometer microscope, specimen and indenter
3) Task Analysis
A) Knowlede:
1) Hardness
2) Hardness Tester
3) Micrometer Microscope
4) Indenters
5) Specimen
B) Skill:
 Identifying the ball indenter and dial indicator.

Handling of
 Identifying the load knob (or load hand lever) and loads changer
apparatus
indicator.
 Unloading and loading of load hand lever.

Manipulation of
 Operating the anvil.
apparatus
 Measuring the diameter (d) of the indentation (impression).
 Operating the anvil just makes contact with ball indenter.

 Unloading and loading of load on specimen with use of hand lever.
Precise
 Measuring the diameter (d) of the indentation (impression) made on
Operations
the specimen using a micrometer microscope.
Activities
 Calculation of B.H.N
4) Teaching Points:
Sl. Time allocation

Teaching point
1 Define the Hardness 3 min
2 Required components 5 min
Select the load, operate the anvil and
3 10 min
measure the diameter of impression

5) Need And Scope Of Experiment
Many new products entering the market today are based on new materials and processes.
These new materials are playing increasingly important roles-supporting innovations and boosting
competitiveness in technology driven industries.
The manufacturing processes and quality requirements for products made using high-tech
materials call for a comprehensive knowledge of process technology in addition to thorough knowledge
of the material’s properties. Among the various mechanical and optical tests used to determine the
characteristics of a material and its suitability for a given application, hardness testing is one of the
most critical. Hardness is defined as the mean pressure a material will support. Hardness testing is
typically undertaken to assess resistance to plastic deformation, a value of tremendous importance to
the determination of part quality in a wide range of industries and applications.
WEIHTAGE WITH
TOTAL
(50)
INDIVIDUALLY
A) Identifying the ball indenter and dial
indicator.
1. Handling of
B) Identifying the load knob (or load hand A B T 5
apparatus lever) and loads changer indicator. 2 3 5
A) Unloading and loading of load hand lever.

2. Manipulati B) Operating the anvil. A B C T
on of C) Measuring the diameter (d) of the 5 5 5 15 15
apparatus indentation (impression).
A) Operating the anvil just makes contact with

ball indenter.
B) Unloading and loading of load on specimen
3. Precise
with use of hand lever. A B C D T
Operations 25
C) Measuring the diameter (d) of the 5 5 5 10 25
/ Activities indentation (impression) made on the
specimen using a micrometer microscope.
D) Calculation of B.H.N
A) Co Operation
B) Co- Ordination
A B C D E T
5 Values C) Communication 5
D) Sharing 1 1 1 1 1 5
E) Leadership

7) Assessment Questions
1. Identify the ball indenter and dial indicator.(LO)

2. Identify the load knob (or load hand lever) and loads changer indicator. (LO)
3. Load and Unload hand lever. (MO)
4. Operate the anvil. (MO)
5. Measure the diameter (d) of the indentation (impression). (MO)
6. Operate the anvil just makes contact with ball indenter. (HO)
7. Load and Unload on specimen with use of hand lever. (HO)
8. Measure the diameter (d) of the indentation (impression) made on the specimen using a
micrometer microscope. (HO)
9. Calculate B.H.N.(HO)
8) Viva Questions:
1. What is the importance of Hardness?

2. Identify the materials, which are the harder materials,
3. How many methods are used to measuring the hardness of the materials?
4. Which ball size is recommended for Brinell’s test?
5. Write the formula for finding the Brinell’s Hardness number?
6. How to differentiate between Hardness and Strength?
7. Which is the hardest material in the world?
8. Which material is used for cutting tools?
9. How to differentiate between Brinell’s and Rockwell’s testing?

LABORATORY SHEET 2.5 (B) ROCKWELL’S HARDNESS TEST
ROCKWELL’S HARDNESS TEST
1) Objective: To determine the hardness number of the given specimen using Rockwell’s Hardness
Tester.
2) Apparatus:
Rockwell hardness tester, specimen and indenter (diamond cone or 1/16” ball)
3) Task Analysis
A) Knowlede:
1) Hardness
2) Hardness Tester
3) Indenter
4) Specimen
B) Skill:

 Identifying the indenter and dial indicator.
Handling of  Identifying the load knob (or load hand lever) and loads changer
apparatus indicator.
 Unloading and loading of load hand lever.

Manipulation of  Operating the anvil.
apparatus  Reading the dial indicator according to type of indenter and loading.
 Operating the anvil just makes contact with ball or diamond indenter.
Precise  Unloading and loading of load on specimen with use of hand lever.
Operations  Reading the dial indicator according to type of indenter and
Activities corresponding load.
 Calculating the R.H.N
4) Teaching Points:
Sl. Time allocation

Teaching point
1 Define the Hardness 3 min
2 Required components 5 min
Select the load, according to indenter
3 10 min
and operate the anvil

5) Need And Scope Of Experiment
Many new products entering the market today are based on new materials and processes.
These new materials are playing increasingly important roles-supporting innovations and boosting
competitiveness in technology driven industries.
The manufacturing processes and quality requirements for products made using high-tech
materials call for a comprehensive knowledge of process technology in addition to thorough knowledge
of the material’s properties. Among the various mechanical and optical tests used to determine the
characteristics of a material and its suitability for a given application, hardness testing is one of the
most critical. Hardness is defined as the mean pressure a material will support. Hardness testing is
typically undertaken to assess resistance to plastic deformation, a value of tremendous importance to
the determination of part quality in a wide range of industries and applications.
WEIHTAGE WITH
TOTAL
(50)
INDIVIDUALLY
Indicator.
1. Handling of
B) Identifying the load knob (or load hand A B T 5
apparatus lever) and loads changer indicator. 2 3 5
A) Unloading and loading of load hand lever. A B C T

2. Manipulatio
B) Operating the anvil.
n of 5 5 5 15 15
C) Reading the dial indicator.
apparatus
A) Operating the anvil just makes contact
with ball indenter.
B) Unloading and loading of load on
3. Precise
specimen with use of hand lever. A B C T
Operations 20
C) Reading the dial indicator according to 5 5 10 20
Activities type of indenter and loading.
D) Calculating the R.H.N
A) Co Operation
B) Co- Ordination
A B C D E T
5 Values C) Communication 5
D) Sharing 1 1 1 1 1 5
E) Leadership

1. Identify the ball indenter and dial indicator.(LO)

2. Identify the load knob (or load hand lever) and loads changer indicator. (LO)
3. Load and Unload hand lever. (MO)
4. Operate the anvil. (MO)
5. Operate the anvil just makes contact with ball indenter. (HO)
6. Load and Unload on specimen with use of hand lever. (HO)
7. Measure the diameter (d) of the indentation (impression) made on the specimen using a
micrometer microscope. (HO)
8. Calculate R.H.N.(HO)
8) Viva Questions:
1. What is the importance of Hardness?
2. Identify the materials, which are the harder materials,
3. How many methods are used to measuring the hardness of the materials?
4. Which ball size is recommended for Rockwell’s test?
5. Write the formula for finding the Brinell’s Hardness number?
6. How to find the Rockwell’s Hardness number?
7. How to differentiate between Hardness and Strength?
8. Which is the hardest material in the world?
9. Which material is used for cutting tools?
10. How to differentiate between Brinell’s and Rockwell’s testing?
11. How many scales on Hardness tester dial?
12. Which scale is used for higher hardness?
13. Which scale is suitable for 1/16” steel ball indenter?

2.6 LABORATORY SHEET TORSION TEST ON SPRINGS
TORSION TEST ON SPRINGS

1) Objective: (i) To determine the modulus of rigidity of the material for the given spring by conducting
the deflection test in tension
(ii) To determine the modulus of rigidity of the material for the given spring by conducting
the deflection test in compression
2) Apparatus: Spring testing machine, Spring(s) and vernier calipers.
3) Task Analysis
A) Knowledge:
1) Components of Spring testing machine
2) Working of Spring testing machine
3) Measuring of Vernier calipers
B) Skill:
● Identifying the components required.

Handling of
● Checking load on the dial gauge.
apparatus ● Opening and closing of oil valve.
● Closing the oil valve

Manipulation of ● Setting of spring between the two jaws by the movement of jaws
apparatus manually/hydraulically
● Check the working of load dial gauge
● Recording dial gauge reading of load and Recording the deflection of

Precise the spring on vertical scale.
Operations/ ● Adjust the load manually/hydraulically and record the dial gauge
Activities reading and Recording the deflection of spring on the scale by
increasing load
4) Teaching Points:
Time allocation
1 Construction and working of Spring testing machine 6 min
2 Specifications of Spring(s) and vernier scale 3 min
3 Calculation of modulus of rigidity 6 min
NITTTR EXTENSION CENTRE ,VIJAYAWADA

 Procedural Precautions:
1) Check the oil valve closing position.
2) Check the dial gauge reading without load.
3) Check the deflection reading on scale without load.
4) Care should be taken while applying the load on spring.
 Safety Precautions:
1) Wear apron
2) Beware of loose clothing while operating
5) Need And Scope Of The Experiment:
The test on springs will gives the value of modulus of rigidity of the spring. The deflection of
the spring depends on load applied, radius of coil, number of turns of the coil, radius of spring wire and
rigidity modulus of the spring
WEIHTAGE WITH
TOTAL
(50)
INDIVIDUALLY
1. Handling of B. Checking load on the dial gauge
A B C T 5
apparatus C. Opening and closing of oil valve
2 1 2 5
A. Closing the oil valve
B. Setting of spring between the two jaws
2. Manipulation of by the movement of jaws A B C T
20
apparatus manually/hydraulically 2 10 8 20
C. Check the working of load dial gauge
A. Recording dial gauge reading of load and

Recording the deflection of the spring on
3. Precise vertical scale.
A B T
Operations B. Adjust the load manually/hydraulically 20
Activities and record the dial gauge reading and 10 10 20
Recording the deflection of spring on the
scale by increasing load
A) Co Operation
B) Co- Ordination
D) Sharing 5
E) Leadership

a) Identify the components required.(LO)

b) Check load on the dial gauge. (LO)
c) Open and close of oil valve. (LO)
d) Close the oil valve.(MO)
e) Set the spring between the two jaws by the movement of jaws manually/hydraulically(MO)
f) Check the working of load dial gauge(MO)
g) Record dial gauge reading of load and Recording the deflection of the spring on vertical scale. (HO)
h) Adjust the load manually/hydraulically and record the dial gauge reading and Recording the deflection
of spring on the scale by increasing load (HO)
8) Viva Questions:
a) How does a spring testing machine works?
b) Where is spring testing machine used?
c) Which is the most important parameter of springs?
d) Differentiate between closed coil and open coil helical springs?
e) What is the function of springs?
f) What is difference between closed coil helical spring and open coil helical spring?
g) What type of stress is involved in helical coil springs?
h) What type of spring is used to transmit small torque?
i) Which material is to use manufacturing of springs?

LABORATORY SHEET 2.7 DEFLECTION TEST ON SIMPLY SUPPORTED BEAM
FLEXURAL TEST ON SIMPLY SUPPORTED BEAM
1) Objective: To determine the Young’s modulus of a simply supported beam (positioned both breadth wise
and depth wise)
2) Apparatus: Beam of different cross-sections and different materials (say mild steel and wood)
Load hanger
Weights
Dial gauge indicator
Knife edge supports
Vernier calipers
Steel rule.
3) Task Analysis
A) Knowledge:
1) Definition of beam and types of beams
2) Definition of Load and types of loads
3) Purpose of Dial gauge indicator
4) Definition of Young’s modulus and Moment of Inertia
5) Relation between Young’s modulus and deflection
B) Skill
 Identifying the components required.

 Measuring the length, width and depth of the given beam.
Handling of
 Identifying the simply supported ends.
apparatus
 Identifying the center point of beam.
 Identifying the 2/3rd length of the beam from right end.
 Placing the rectangular beams on Knife edge supports.

Manipulation of  Adjusting the dial gauge pointer to bottom of the simply supported
apparatus beam.
 Placing the load hanger at midpoint of the beam.
 Placing the required loads on load hanger located at the center of the
beam.
Precise  Recording the dial gauge deflections to the corresponding loads of the
Operations beam.
Activities  Calculating moment of inertia for both beams.
 Calculating the Young’s modulus for both beams.

4) Teaching Points:
Sl. Time allocation

Teaching point
1 Definition of Beam and types of beams 2 min
2 Definition of Load and types of loads 2 min
3 Explanation of apparatus 1 min
4 Measuring procedure for given beam 1 min
Explanation of arrangement of simply
5 1 min
supported beam
6 Procedure to calculate Young’s modulus 10 min
7 Need and scope of experiment 2 min
8 Precautions 1 min
 Precautions:
 Make sure that beam and load are placed in a proper position.
 The cross- section of the beam should be large.
 Note down the readings of the Vernier scale carefully.

WEIHTAGE WITH
TOTAL
(50)
INDIVIDUALLY
B) Measuring the length, width and depth of
1. Handling of the given beam A B C D E T
5
apparatus C) Identifying the simply supported ends. 1 1 1 1 1 5
D) Identifying the center point of beam.
E) Identifying the 2/3rd length of the beam.
A) Placing the rectangular beam on simply
supported ends.
2. Manipulatio A B C T
B) Adjusting the dial pointer to bottom of the
n of 2 4 4 10 10
simply supported beam.
apparatus C) Placing the load hanger at midpoint of the
beam.
A) Placing the required loads on load hanger
located at the center of the beam.
B) Recording the dial gauge deflections to
3. Precise
the corresponding loads of the beam. A B C D T
Operations 30
C) Calculating moment of inertia for both 3 5 10 12 30
Activities beams.
D) Calculating the Young’s modulus for both
beams.
A) Co Operation
B) Co- Ordination
A B C D E T
1 1 1 1 1 5
D) Sharing
E) Leadership
a) Identify the components required.

b) Measure the length, width and depth of the given beam
c) Identify the simply supported ends.
d) Identify the center point of beam.
e) Identify the 2/3rd length of the beam.
f) Place the rectangular beam on simply supported ends.
g) Adjust the dial pointer to bottom of the simply supported beam.
h) Place the load hanger at midpoint of the beam.
i) Place the required loads on load hanger located at the center of the beam.
j) Record the dial gauge deflections to the corresponding loads of the beam.
k) Calculate moment of inertia for both beams.
l) Calculate the Young’s modulus for both beams.

7) Viva Questions:
a) Which position of the beam carries maximum load based on rigidity?
b) How do you find out the least count of a Vernier caliper? (Lower order)
c) Why is young’s modulus higher in transverse direction?
d) What is the effect of neutral axis after the deflection?
e) Give any three applications of simply supported beam?
f) Why is the deflection maximum at centre than the supports?
g) Where the slope is maximum and minimum?
h) What is the effect of moment of inertia on young’s modulus?
i) Why is Young’s modulus calculated on one axis of the beam?
j) What is meant by transverse loading on a beam? (Lower order)
k) Why is cross section of beam rectangular rather than circular?
l) Which location of the beam gets higher deflection? (Higher order)
m) How is slope different from deflection? (Higher order)
n) What will the Maximum Deflection in a beam when its depth is doubled in Strength of
Materials?

LAB SHEET 2.8 STUDY OF MICRO STRUCTURE OF METALS AND ALLOYS
STUDY OF MICRO STRUCTURE OF METALS AND ALLOYS

1) Objective: a) To prepare and observe the Micro-structure of Gray cast iron.
b) To prepare and observe the Micro-structure of Brass.
2) Apparatus:
 Set of emery papers 220, 300, 400, 500, 600, 1000,
 Polishing papers 1/0, 2/0, 3/0 and 4/0.
 Grinding wheel,
 Disc polishing machine,
 Microscope,
 Brass and Gray cast iron specimen,
 Lavigated polishing alumina powder,
 Etchants.
3) Task Analysis
A) Knowledge:
1) Sequence of emery papers and polishing papers to be used.
2) Handling of Microscope.
3) Various Etchants to be applied.
4) Investigation of microscopic structure.
B) Skill:
● Identifying the components to be studied.

Handling of
● Order of applying emery papers.
apparatus
● Setting of microscope.
● Specimen pressed against the emery papers and polishing papers.

● Disc polishing method for fine finishing of specimen.
Manipulation of
● Etchants should be applied for a particular time and should be
apparatus
washed out.
● Handling of microscopic lens.
● Sequence of polishing towards mirror finishing.

Precise Operations
● Selection of etchants as per recommended.
Activities
● Adjustment of microscope and observing the structure of specimen.
NITTTR EXTENSION CENTER-VIJAYAWADA

4) TEACHING POINTS:
Time allocation
1 Preparation of specimens 5 min
2 Polishing of specimen and applying of etchants 4 min
3 Observation of structure through microscope 6 min
 PROCEDURAL PRECAUTIONS:
1) Check the Grinding be done on the emery in one direction.
2) Ensure mirror polished surface.
3) Etchant should be applied for a particular time and washed away.
4) Care should be taken the polished surface.
5) Handling the Microscope properly.
 SAFETY PRECAUTIONS:
1) Wear apron.
2) Beware of loose clothing while operating.
5) NEED AND SCOPE OF THE EXPERIMENT:
1. Study the characteristics and mechanical properties of a Metals and Alloys.
2. To predict the behavior of a component this is important while predicting the failure of the
component at certain conditions.

6) SCHEME OF EVALUATION:
WEIHTAGE WITH
TOTAL
(50)
INDIVIDUALLY
1. Handling of B) Order of applying emery papers
A B C T 5
apparatus C) Setting of microscope
2 2 1 5
A) Specimen pressed against the emery

papers and polishing papers
B) Disc polishing method for fine finishing
2. Manipulation of specimen. A B C D T
20
of apparatus C) Etchants should be applied for a 5 5 5 5 20
particular time and should be washed
out.
D) Handling of microscopic lens
A) Sequence of polishing towards mirror
finishing.
3. Precise
B) Selection of etchants as per A B C T
Operations 20
recommended. 5 5 10 20
Activities
C) Adjustment of microscope and
observing the structure of specimen
A) Co Operation
B) Co- Ordination
D) Sharing 5
E) Leadership
a) Identify the components required.

b) Order of apply emery papers
c) Specimen pressed against the emery papers and polishing papers
d) Disc polishing method for fine finishing of specimen.
e) Etchants should be applied for a particular time and should be washed out.
f) Handling of microscopic lens
g) Sequence of polishing towards mirror finishing.
h) Selection of etchants as per recommended.
i) Adjustment of microscope and observing the structure of specimen

8) VIVA QUESTIONS:
1. What is need for studying micro structure?

2. How will you prepare the specimen to make study of micro structure?
3. What are the observations of micro structure of given specimen before polishing after polishing?
4. What do you understand from the obtained micro structure?
5. What do you mean by alloy?
6. What is the composition of brass?
7. What is the composition of Gray cast iron?
8. Why grinding is performed before polishing?
9. Why the sequences of emery paper grades are used for finishing?
10. Why etchants are applied on specimen to find microstructure?
11. What are the etchants applied for gray cast iron and brass specimen?
12. Which type of microscope used to find microstructure?
13. What is meant by magnification of microscope?
14. What is the form of carbon in gray cast iron micro structure?

WORK SHEETS
WORK SHEET 3.1 TENSION TEST
WORK SHEET
NAME OF THE STUDENT: INSTITUTION:

PIN NUMBER: DATE OF EXPERIMENT:
BRANCH: EXPERIMENT NO:
1. Title of the experiment:

2. Objective of the Experiment:
3. Apparatus/Tools Required:
4. Procedure:

5. Observations:
Least count of vernier callipers:

Diameter of rod,D:
Initial Gauge length,L:
Load at yield point:
Ultimate load:
Breaking load:
Final Gauge length,∆L:
Diameter at fractured portion ,D1:
6. Table:
S.NO Load,P(KN) Elongation, ∆l( mm) Tensile Stress, Stain,e=∆L/L Young’s modulus,
E= σ /e(KN/m2)
σ=P/A(KN/m2)

7. Graphs: Plot the graph between stress(y-axis) and strain(x-axis)
8. Calculations :
1. Original area of rod,A=πd2/4=---------------------------------------------m2

2. Reduced area of rod,A1=πd12 /4=------------------------------------------m2
3. Ultimate strength=ultimate load/ original area=----------------------N/m2
4. Yield strength=load at yield point/original area=--------------------- N/m2
5. Percentage of elongation=((L-∆L)/L)x100=--------------------------------------
6. Percentage area reduction=((A-A1)/A)x100=----------------------------------
7. Young’s modulus,E=------------------------------------------------------------------
9.Results
1. % of elongation=-------------------------------------------------
2. % of area reduction=-------------------------------------------
3. Youngs modulus=-----------------------------------------------

10. Scheme of Evaluation:
WEIHTAGE WITH TOT

Category of Skill SUB TASK COMPETENCY LEVEL AL
INDIVIDUALLY (50)
required.
B) Operating controller for
1. Handling of
moving jaws. A B C T
apparatus
C) Fixing extensometer.
D)
A) Measuring gauge length

and diameter.
2. Manipulatio A B C D T
B) Fixing job between UTM
n of
jaws by controller.
apparatus
C) Loading
D) Hydraulic pump operation
A) Fixing job between UTM
jaws by controller.
B) Rate of loading
C) Note down readings of load
and extensions from digital
3. Precise panel board A B C D E F T
Operations/ D) Precise operation of pump
Activities E) Calculating Young’s
modulus, % of elongation,
% of reduction in area.
F) Draw stress-strain curve.
A) Co Operation
4. Values C) Communication
D) Sharing
E) Leadership

WORK SHEET 3.2 COMPRESSION TEST
WORK SHEET
Name of the student: Date of exp:

PIN: Branch:
Institution: Exp no:
1. Title Of Experiment:
2. Objective Of The Experiment:
3. Equipments Required:
S.No Name Quantity
4. Procedure:

5. Observations:
1.Ultimate Load :
2. Dimensions of concrete cube: LXBXH
Length (L) = ____________
Breadth (B) = ___________
Height (H) = ___________
6. Calculations:
Compressive strength =______________________
7. Results

8. Scheme Of Evaluation:
WEIGHTAGE WITH
TOTAL
(50)
INDIVIDUALLY
1. Handling of B) Measuring the dimensions of a given
A B T
apparatus Concrete cube.
A) Connecting the power supply and

placing the specimen. A B C T
2. Manipulation
B) Operating the load valve and back oil
of apparatus
valve.
C) Observing the rate of loading
A) Checking of both the valves in closed
position before start of the
3. Precise A B C T
experiment.
Operations
B) Operating the load valve.
Activities
C) Observing the readings and noting of
the final reading.
A) Co Operation
B) Co- Ordination T
D) Sharing
E) Leadership

WORK SHEET 3.3 SHEAR TEST

PIN: Branch:
Institution: Exp no: 04
1. Title Of Experiment:
2. Objective Of The Experiment:

3. Equipments Required:
4. Shear Attachment :

5. Procedure:
6. CALCULATIONS:
Diameter of the Rod, d = ………
Cross-section area of the Rod = A =
where‘d’ is the actual diameter of the specimen
Load taken by the Specimen at the time of failure, P =………
The shear strength shall be calculated from the following formulae = N/mm
Shear strength of the given specimen = ………...

7. Table:
Diameter of specimen Area of cross section Failure load , Shear strength
8. Result:
9. Scheme Of Evaluation:
Weightage with
Marks
Category of Skill SUB TASK competency level
awarded
individually
1. Handling of B) Identifying the specifications of the A B T
apparatus specimen
A) Checking the power supply and working of

UTM remote
B) Checking start and stop buttons, Opening
2. Manipulation A B C T
and closing valves.
of apparatus C) Checking the position of specimen in shear
attachment
A) Measuring the diameter of the specimen and

fixing the Specimen in the Shear attachment.
3. Precise
B) Keeping the shear equipment on the fixed A B T
Operations
jaw of UTM and apply the load slowly at right
Activities angles to the axis of piece through the
central block and noting of load at fracture.
A) Co Operation
B) Co- Ordination
D) Sharing 5
E) Leadership

WORK SHEET 3.4 IMPACT TEST (IZOD and CHARPY)
IMPACT TEST (IZOD and CHARPY)

PIN: Branch:
1) Title of Experiment:
2) Objective of the experiment:
3) Equipment Required:
4) Procedure
(a) Izod Test:

(b) Charpy Test:
5) Observations:
(a)Izod Test:
a. Type of material used:
b. Size of the specimen used:
c. Type and position of V-notch:
d. Depth of V-notch:
e. Maximum capacity of pendulum:

Scale reading Impact resistance

Materials Scale reading
S.No. without
after fracture(E2) (E1-E2)
specimen(E1)
1
2
3
(b) Charpy Test:

a. Type of material used:
b. Size of the specimen used:
c. Type and position of V-notch:
d. Depth of V-notch:
e. Maximum capacity of pendulum:
Scale reading Impact resistance
Materials Scale reading
S.No. without
after fracture(E2) (E1-E2)
specimen(E1)
1
2
3
Result:

9. Scheme of Evaluation:
WEIHTAGE WITH
Awarded
(50)
INDIVIDUALLY
1. Handling A. Identifying the components required.

of B. Using of allen key to fix striking hammer. A B C T
apparatus C. Fixing striker to striking hammer
A. Fixing the one end of test specimen in jaws.

2. Manipulati
B .Adjusting the striking hammer to test A B C T
on of
specimen and lock it.
apparatus
C. Adjusting the dial needle to extreme position.
A. Preparing the specimen with 450 notch.

B. Recording the dial reading after releasing the
3. Precise hammer without test specimen.
A B C T
Operation C. Recording the dial reading after releasing the
s Activities hammer with test specimen.
A) Co Operation
B) Co- Ordination
D) Sharing 5
E) Leadership
Total marks awarded 50
Signature of student: Signature of teacher:

WORK SHEET 3.5 (A) BRINELL’S HARDNESS TEST
WORK SHEET
Name of the student: Date of Exp:

PIN: Branch:
1) Title Of Experiment:
2) Objective Of The Experiment:
3) Equipments Required:
S.No Name Quantity
4) Procedure:

5) Observations:
S. material Dia. of the indenter Dia. of ball indenter Applied Load BHN
No d (mm) D (mm) (Kgf)
6) Calculations:

7) Result:
Hardness of the given material is ___________ BHN
WEIHTAGE WITH
TOTAL
(50)
INDIVIDUALLY
indicator.
1. Handling of
B) Identifying the load knob (or load hand A B T
apparatus lever) and loads changer indicator.
A) Unloading and loading of load hand lever.

C) Manipulatio B) Operating the anvil.
n of C) Measuring the diameter (d) of the A B C T
apparatus indentation (impression).

with ball indenter.
D) Precise
specimen with use of hand lever. A B C D T
Operations
C) Measuring the diameter d of the
Activities indentation (impression) made on the
specimen using a micrometer microscope.
D) Calculating the B.H.N
A) Co Operation
B) Co- Ordination
A B C D E T
A) Values C) Communication
D) Sharing
E) Leadership

WORK SHEET 3.5 (B) ROCKWELL’S HARDNESS TEST
WORK SHEET
Name of the student: Date of Exp:

PIN: Branch:
2) Objective Of The Experiment: __________________________________________________
S.No Name Quantity
4) Procedure:

5) Observations:
S. No Material Rockwell scale Weight Indenter RHN trials

1
6) Calculations:

7) Result:
WEIHTAGE WITH
TOTAL
(50)
INDIVIDUALLY
indicator.
1 Handling of
B) Identifying the load knob (or load hand A B T
apparatus lever) and loads changer indicator.
A) Unloading and loading of load hand lever. A B C T

2 Manipulatio
B) Operating the anvil.
n of
C) Reading the dial indicator.
apparatus
with ball indenter.
3 Precise
specimen with use of hand lever. A B C D T
Operations
C) Reading the dial indicator according to
Activities type of indenter and loading.
D) Calculating the R.H.N
A) Co Operation
B) Co- Ordination
A B C D E T
4 Values C) Communication
D) Sharing
E) Leadership

3.6 WORK SHEET TORSION TEST ON SPRINGS
WORK SHEET
PIN: Branch:
1) Title Of Experiment:.
3) Equipment Required:
A) Procedure (For Tension Test):
NITTTR EXTENSION CENTRE VIJAYAWADA

(B) Procedure (For Compression Test):

4) Observations Table (For Tension Test)
S.No. Load (W) Deflection  Stiffness of Modulus of Rigidity

In KN (in mm) Spring=W/  ‘N’
(N/m) (N/mm2)
1
2
3
4
5
6
5) Calculations:

6) Observations Table (For Compression Test)
S.No. Load (W) Deflection  Stiffness of Modulus of Rigidity

In KN (in mm) Spring=W/  ‘N’
(N/m) (N/mm2)
1
2
3
4
5
6
7) Calculations:

8) Result:
WEIHTAGE WITH
Awarded
(50)
INDIVIDUALLY
1. Handling of B. Checking load on the dial gauge
A B C T
apparatus C. Opening and closing of oil valve
A. Closing the oil valve

B. Setting of spring between the two jaws
2. Manipulation by the movement of jaws A B C T
of apparatus manually/hydraulically
C. Check the working of load dial gauge
A. Recording dial gauge reading of load and

Recording the deflection of the spring
3. Precise on vertical scale.
A B T
Operations B. Adjust the load manually/hydraulically
Activities and record the dial gauge reading and
Recording the deflection of spring on
the scale by increasing load
A) Co Operation
B) Co- Ordination
D) Sharing 5
E) Leadership
Total marks awarded 50

WORKSHEET 3.7 DEFLECTION TEST ON SIMPLE SUPPORTED BEAM
WORK SHEET
PIN: Branch:
4) Equipment Diagram:

5) Procedure:

6) Observation And Recording:
Least Count of calipers …………………
Least count of dial gauge …………………
Span of beam …………………
Total Depth of the beam ………………….
Width of the beam …………………..
For Depth of the beam:
S.No Main Scale reading V.C.R M.S.R+ (V.C.R  L.C)
Average

L
For Steel and wood: Load placed   mid span of the beam on a longitudinal (Width wise) direction:
2
Young’s modulus
Deflection reading Deflection reading in
WL3
in divisions "mm" E= , N mm 2
S.No Load ,W 48δI
(in kg ) Mild
Wood Mild Steel Wood Mild Steel Wood
Steel
1
2
3
4
5
6
7
8
9
10
L
For Steel and wood: Load placed   mid span of the beam on a longitudinal (Depth wise) direction:
2
Young’s modulus
WL3
S.No Load ,W 48δI
(in kg ) Mild
Steel
1
2
3
4
5
6
7
8
9
10

2L
For Steel and wood: load placed from right side support of the beam on longitudinal (Widthwise)
3
direction:
Young’s modulus
WL3
S.No Load ,W 48δI
(in kg ) Mild
Steel
1
2
3
4
5
6
7
8
9
10
2L
For Steel and wood: load placed from right side support of the beam on lateral (Depth wise))
3
direction:
Young’s modulus
WL3
S.No Load ,W 48δI
(in kg ) Mild
Steel
1
2
3
4
5
6
7
8
9
10

7) Result :
WEIHTAGE WITH
TOTAL
(50)
INDIVIDUALLY
required.
B) Measuring the length, width and
1. Handling depth of the given beam
A B C D E T
of C) Identifying the simply supported
apparatus ends.
D) Identifying the center point of beam.
E) Identifying the 2/3rd length of the
beam.
A) Placing the rectangular beam on
simply supported ends.
2. Manipulati A B C T
B) Adjusting the dial pointer to bottom
on of
of the simply supported beam.
apparatus C) Placing the load hanger at midpoint
of the beam.
A) Placing the required loads on load
hanger located at the center of the
beam.
B) Recording the dial gauge deflections
3. Precise A B C D T
to the corresponding loads of the
Operations
beam.
Activities C) Calculating moment of inertia for
both beams.
D) Calculating the Young’s modulus for
both beams.
A) Co Operation
D) Sharing
E) Leadership
Total 50
Signature of Student : Signature of Lecturer:

WORK SHEET 3.8 STUDY OF MICRO STRUCTURE OF METALS AND ALLOYS
WORK SHEET
PIN: Branch:
S.No Name Quantity

1
2
3
4
5
6
7
8
4) Micro Structures Of
(a) Gray Cast Iron
1
NITTTR EXTENSION CENTRE -VIJAYAWADA
(b) Brass
5) Procedure:
2
6) Observations:
S.NO To be observed What is observed
microstructure of given
1
material
Structural
characteristics of
2
materials
What kind of structure

3 it has
3
WEIHTAGE WITH
TOTAL
INDIVIDUALLY
1. Handling of B) Order of applying emery papers
A B C T
apparatus C) Setting of microscope
A) Specimen pressed against the emery

papers and polishing papers
B) Disc polishing method for fine finishing
2. Manipulation of specimen. A B C D T
of apparatus C) Etchants should be applied for a
particular time and should be washed
out.
D) Handling of microscopic lens
A) Sequence of polishing towards mirror
finishing.
3. Precise
B) Selection of etchants as per A B C T
Operations
recommended.
Activities
C) Adjustment of microscope and
observing the structure of specimen
A) Co Operation
B) Co- Ordination
D) Sharing 5
E) Leadership
Total marks awarded
4
EXPERIMENTAL METHODOLOGIES
EXPERIMENTAL METHOLOGY 4.1 TENSION TEST
1) Description: A Universal testing machine (UTM) is used to test the mechanical properties
(tension, compression etc.) of a given test specimen by exerting tensile, compressive or
transverse stresses.
2) Theory : - The Universal Testing Machine consists of two units.

1) Loading unit 2) Control panel.
The UTM works on an oil pressure system. It consists of two units namely. , the
straining and the pumping and load – measuring units. The straining unit houses a cylinder
mounted on four sturdy columns..The intermediate cross-head of the machine, which is
movable, is hung from a position, which moves inside the cylinder due to hydraulic pressure
of the oil. The bottom of the cylinder act as the top cross-head of the machine. The bottom
cross-section can work manually. The straining unit has suitable arrangements to hold wedge
grips, compression platforms and bending dogs. The intermediate cross-head can be raised,
lowered or kept in any desired position by operating a hydraulic push from the panel board.
It may be noted that this operation is must for fixing the specimen only and for loading it.
The pumping and load-measuring unit of the machine has the following dial
and control devices.1)The load indicator2)The chart 3)The straining lever 4)The
straining rate control valve and 5)The dwell valve. The load indicator dial is calibrated
in four ranges i)0-40KN ii)0-100KN iii)0-200KN iv)0-400KN setting the range control
lever in the appropriate position affects the change of range.
For recording the load-extension diagram, the machine is equipped with an

automatic graph-recorder. It comprises of a recording mechanism that controlled by the
dynamometer and a roller that drives on an writing board over which the chart moves. This
corresponds to the whole power measuring range, to transfer of load to the chart is affected
immediately by means of a narrow tape. The tensile forces are recorded along the vertical
axis and the elongation is recorded along the horizontal axis.

Fig (i). UTM WITH PARTS
3) Procedure:-
 Measure the diameter of the given steel rod using vernier calipers at three places along
the length of the specimen and calculate the diameter of the rod.
 The gauge length is marked on the specimen and is placed in between the grips of the
UTM.
 The initial reading of the extensometer is noted. If it is not set to zero.
 Apply the load gradually and increase it at the uniform rate.
 Tensile stress is setup in the material and elongation takes place. At regular intervals of
tensile load p and elongation are noted and tabulated.
 Continue the load application till fracture occurs and measure the final gauge length is
measured to find the total percentage elongation. By joining the two broken halves of
the specimen together, measure the final length and diameter of specimen.

4) Precautions:-
 Maintain distance from while the experiment is processing

 The specimen should be prepared in proper dimensions.
 The specimen should be held properly between the jaws.
 Take reading carefully.
 After breaking the specimen switch off the machine.
5) Graphs:
6) Observations:
Least count of vernier callipers: mm
Diameter of rod,D: mm
Initial Gauge length,L: mm
Load at yield point: N
Ultimate load: N
Breaking load: N
Final Gauge length,∆L: mm
Diameter at fractured portion ,D1: mm

7) Table:
S.NO Load,P(KN) Elongation, ∆l(mm) Tensile Stress, Stain,e=∆L/L Young’s modulus,
σ=P/A(KN/m2) E = σ /e(KN/m2)
8) Graphs: Plot the graph between stress(y-axis) and strain(x-axis)
9) Calculations :
1. Original area of rod,A=πd2/4=---------------------------------------------m2
2. Reduced area of rod,A1=πd12 /4=------------------------------------------m2
3. Ultimate strength=ultimate load/ original area=----------------------N/m2
4. Yield strength=load at yield point/original area=--------------------- N/m2
5. Percentage of elongation=((L-∆L)/L)x100=--------------------------------------
6. Percentage area reduction=((A-A1)/A)x100=----------------------------------
7. Young’s modulus,E=------------------------------------------------------------------

EXPERIMENTAL METHODOLOGY 4.2 COMPRESSION TEST
COMPRESSION TEST
1) Description:
 COMPRESSION TESTING MACHINE: Compression testing equipment is widely used

in industry and lab works. Compression test machine is electrically operated with dual
display load gauge-2000 KN x 1 KN/Division.
 Capacity 2000KN(200 Tonnes)
 Main features: High precision and resolution, user friendly software, performance of
many types of tests, real time monitoring of test data.
 COMPONENTS OF COMPRESSION TESTING MACHINE: The following main

components are
a. Loading unit
b. Control panel
c. Hydraulic system
d. Load measuring and indicating system for Electronic machine
a. Loading unit: It consists of base at its center, hydraulic cylinder, piston and two
screws. Across head is mounted on the screws and is driven by a motor for rapid
adjustment of test height. A table is mounted on the piston.
b. Control panel: It consists of hydraulic system with power pack, load measuring and
indicating system and electrical system
c. Hydraulic system: It consists of hydraulic power pack with directly driven radial
plunger pump power of consists of oil filter, oil strainer, air breather, drain plug, oil
level indicator etc. A pressure compensated flow control valve is provided for
controlling the oil flow to cylinder by achieving desired piston speed.
d. Load measuring and indicating system for Electronic machine: The oil
pressure in the main cylinder is transferred to an electronic pressure transducer
which gives proportional electronic signal. Displacement measurement is carried out
by a rotary encoder mounted on the base. The linear motion of piston is converted
into rotary motion and the encoder undergoes angular displacement. This gives
proportional electronic signal for deflection.

2) Theory:
The goal of a compression test is to determine the behavior or response of a material

while it experiences a compressive load by measuring fundamental variables such as stress,
strain and deformation.
3) Procedure:
 Note the identification marks, size and weight of the concrete cube (specimen).
 Start the machine after ensuring sufficient lubrication.
 Place the specimen centrally on the lower fixed jaw.
 Lower the upper movable jaw by means of hand operated lever until it touches the top
of the cube.
 Apply the load gradually by operating the load valve.
 Observe the load and deflection readings.
 Note the final reading (ultimate point) when the rate of loading displays a negative
value.

4) Observations:
1. Load = N
2. Dimensions of concrete cube: LXBXH
Length (L) = mm
Breadth (B) = mm
Height (H) = mm
5) Calculations:
Surface area= length X breadth =________________

Compressive strength =________________
S.No. Sample size Breaking Load(KN) Surface area Compression

(mm3) strength(KN/mm2)
6) Result:
Ultimate compressive strength = _______________

EXPERIMENTAL METHODOLOGY 4.3 SHEAR TEST
SHEAR TEST
1) Description:
Shear stress is defined as the shear force which acts on a particular area and it is
responsible for causing a deformation of material through motion along the plane or a no. of
planes operating parallel to the applied stress. Shear stress eventuates in either solid or a liquid;
it acts as a parallel force to the surface in solid materials where as, it is related to fluid viscosity
in liquid.
Along with bending moment, shear stress always comes to act when a beam is loaded.
However, the effect of shear stress is negligible in compression to bending stress. But in design
calculation, the shear stress sometimes shows the utmost importance as it is responsible for the
breakdown of an object. This test is known as a double shear stress because the sample is
operated under load from both sides until it shears.
Universal Testing Machine is used for determining Tensile, Compression, Bending and
Shear stress. UTM is divided in to screw type, and hydraulic type where the hydraulic one is
easier to operate and they have a testing and control unit which is connected through a
hydraulic pipe.
2) Theory:
 In direct shear test, the shearing stress is considered as uniformly distributed over the entire
cross section.
 The shear force is applied by a suitable test rig, two different cases of shearing may arise;
i.e., single shear and double shear.
 In single shear shearing occurs across a single surface and in double shear shearing occurs
across two surfaces.
 Knowledge of shear failure is important while designing any structures or machine
components.
 Shear force causes the surface to go out of the alignment with each other and thus the
material fails.
 The shearing force P in each section is P = F/2, it can be concluded that the average shearing
stress is the maximum load divided by the combined cross-sectional area of the two planes
This shall be calculated from the following formula:

 The shearing force P in each section is P = F/2, it can be concluded that the average shearing
stress is the maximum load divided by the combined cross-sectional area of the two planes
This shall be calculated from the following formula:
 Shear strength of the specimen is determined by inserting a cylindrical specimen through

round holes in three hardened steel blocks, the centre of which shall be pulled (or pushed)
between the other two so as to shear the specimen on two planes.
 In this test a suitable length of cylindrical specimen is subjected to double shear loading
using a suitable test rig in a testing machine under a compressive load or tensile pull and
recording the maximum load P to fracture.
 The speed of testing or the rate of separation of the cross-heads, at any moment during the
test, shall not be greater than 10 mm/min.
Shear stress:
 It is produced in a body when it is subjected to two equal and opposite forces spaced at an
infinite decimal distance or tangentially across the resisting section.
 Generally it is difficult to produce conditions of pure shear as some bending effect is likely to
occur due to shearing load resulting in equal and opposite forces at a small finite distance.

3) Procedure:
 Take the mild steel specimen and determine the width ‘b’& thickness ‘T’ of the mild
steel specimen using vernier calipers.
 The mild steel specimen is placed in the shear attachment and placed into the universal
testing machine (UTM).
 The machine is switched on & the load is gradually increased until the specimen and the
load required to fracture is recorded.
 Select the suitable range of loads and space the corresponding weight in the pendulum
and balance it if necessary with the help of small balancing weights.
 Note down the load at which the specimen shears.
 Stop the machine and remove the specimen.
 Repeat the experiment with other specimens.
4) Calculations:
Diameter of the Rod, d = ……… mm
Cross-section area of the Rod = A = mm2
where‘d’ is the actual diameter of the specimen

Load taken by the Specimen at the time of failure, P =……… N
The shear strength shall be calculated from the following formulae = N/mm2
Shear strength of the given specimen = ………... N/mm2

5) Observation Table:
Diameter of specimen Area of cross section Failure load ,P(N) Shear strength (N/mm2)
(mm) (A= )mm2
6) Result:
The shear strength of mild steel is found to be = …………….N/mm2

EXPERIMENTAL METHODOLOGY 4.4 IMPACT TEST (IZOD and CHARPY)
IMPACT TEST
1) Description:
The impact test is a method for evaluating the toughness, impact strength and notch
sensitivity of engineering materials. ... The quantity usually measured is the energy absorbed in
breaking the specimen in a single blow, as in the Charpy impact test and Izod impact test.
2) Theory:
The impact test is performed to examine the toughness of a given material. Toughness
indicates the maximum energy absorbed by the material at failure. The loads may be broadly
classified as static load and Dynamic load. The behaviour of the material differs when it is
subjected to dynamic loads in comparison to static loads.
Impact test is the most commonly used dynamic load test that is done to characterize
the ductile brittle transition behavior in material. The impact test is done by placing a square
shaped V-notched specimen in the machine. Notched-bar impact test of metals provides
information on failure mode under high velocity loading conditions leading sudden fracture
where a sharp stress raiser (notch) is present. The energy absorbed at fracture is generally
related to the area under the stress-strain curve which is termed as toughness in some
references. Brittle materials have a small area under the stress-strain curve (due to its limited
toughness) and as a result, little energy is absorbed during impact failure.
As plastic deformation capability of the materials (ductility) increases, the area under
the curve also increases and absorbed energy and respectively toughness increase. Similar
characteristics can be seen on the fracture surfaces of broken specimens. The fracture surfaces
for low energy impact failures, indicating brittle behavior, are relatively smooth and have
crystalline appearance in the metals. On the contrary, those for high energy fractures have
regions of shear where the fracture surface is inclined about 45° to the tensile stress, and have
rougher and more highly deformed appearance, called fibrous fracture. Two standardized tests,
the Charpy and Izod, were designed and used extensively to measure the impact energy.
The load is applied as an impact blow from a weighted pendulum hammer that is
released from a position at a fixed height h. The specimen is positioned at the base and with the

release of pendulum, which has a knife edge, strikes and fractures the specimen at the notch.
The pendulum continues its swing, rising a maximum height h ' which should be lower than h
naturally. The energy absorbed at fracture E can be obtained by simply calculating the difference
in potential energy of the pendulum before and after the test such as, E = m.g.(h-h ') where m is
the mass of pendulum and g is the gravitational acceleration. Impact test can be used for
determining the ductile to brittle behavior in a material.
Impact testing machine used for this experiment contains a heavy swing pendulum. This
pendulum has the maximum capability of impacting energy of 300J. A scale is provided in the
machine and an indicator will move on this scale when pendulum is allowed to swing from its
horizontal static position to impact the V-notched specimen. There is an anvil at the bottom of
the machine where V-notched specimen is supported as a beam in horizontal position.
3) Procedure
(a) Izod Test
The following tasks are to be carried out sequentially in order to determine the
Impact Energy (Toughness) of a given material (MS).
 The pendulum is released by actuating the trigger without any specimen in the anvil. With
the help of the pointer the potential energy in the pendulum is noted.
 The reading on the scale E1 gives the loss of energy in the bearing and wind pressure.

 Now the pendulum is replaced in its original position and the pointer is kept parallel to it. By
operating the screw wheel, the dies are separated and the specimen is inserted in the
operating between the two dies in the form of Cantilever and positioned accurately by
means of the setting edge with the notch facing the pendulum hammer.
 The pendulum is raised from the gate stop and placed on the spring loaded trigger. When
the handle of the trigger is operated to release the pendulum, it swings and strikes the test-
piece with kinetic energy that is equal to potential energy.
 on striking, the test specimen breaks or fails and with the residual energy the pendulum
swings on the other side. This reading E2 is noted. The difference of the two energies i.e.,(E2-
E1) gives the impact (or impact strength) of the material.
(b). Charpy Test

The following tasks are to be carried out sequentially in order to
determine the Impact Energy (Toughness) of a given material (MS).
 Release the pendulum is by actuating the trigger without any specimen in the anvil. With
the help of the pointer the potential energy in the pendulum is noted.
 Take the reading on the scale E1 which gives the loss of energy in the bearing and wind
pressure.
 Now the pendulum is replaced in its original position and the pointer is kept parallel to it. By
operating the screw wheel, the dies are seperated and the specimen is inserted in the
operating between the two dies in the form of SSB and positioned accurately by means of
the setting edge with the back of the notch facing the pendulum hammer.
 The pendulum is raised from the gate stop and placed on the spring loaded trigger. When
the handle of the trigger is operated to release the pendulum, it swings and strikes the test-
piece with kinetic energy that is equal to potential energy.
 On striking, the test specimen breaks or fails and with the residual energy the pendulum
swings on the other side.
 This reading E2 is noted. The difference of the two energies i.e.,(E2-E1) gives the impact (or
impact strength) of the material.

4) Observations:
Type of material used : Mild Steel
Size of specimen used : Charpy test – 75mm x 10mm x 10 mm &
Izod test – 55mm x 10mm x10 mm
Type of notch : V-notch (450), 28mm for charpy test & 27.5 for Izod test from one end of
specimen.
Depth of notch : 2mm.
5) Precautions:
 Care should be taken that the pendulum is locked with the spring lever when it is in
its maximum potential energy position.
 The observer should not stand opposite to the swinging pendulum.
 Readings should be taken without parallax error.
 To bring the pendulum to rest when swinging the breaks should be applied gently
when it is swinging from lowest position to highest position.
6) Result:
Toughness of the given Specimen:

EXPERIMENTAL METHODOLOGY 4.5 (A) BRINELL’S HARDNESS TEST
BRINELL HARDNESS TEST
1) Description:
Brinell Hardness Tester:
Application: Brinell hardness tester is mainly used to detect the hardness of the raw
materials and semi finished products.
Type Of Indenter: Ball Indenter of 2.5 and 5 mm
Testing Type Of Material:
Ball Indenter 2.5 Mm: non ferrous metals, soft iron, steel castings, malleable iron and
cast iron
Ball Indenter 5 Mm: Light alloy casting and forging alloy, die casting alloy, brass, copper,
aluminum, nickel and bronze alloy.
Test Force: 187.5kg and 250kg of total load (initial load 10 kgs) for ball indenter of
diameter 2.5 and 5 mm respectively
Micrometer Microscope:
It is used for the measurement of diameter of indentation of the ball indenter (d).
2) Diagram:

3) THEORY:
Hardness is the property of the material by which it offers resistance to scratching or

indentation. Sometimes hardness is defined as resistance to penetration, abrasion and cutting.
The method of testing consists of indenting the material with a 10 mm diameter
hardened and tempered steel ball subjected to a definite load. The load is maintained for a
definite period (usually 15 or 20 seconds), after which the load is removed and the diameter of
the impression (indentation) is measured. The hardness of the material, expressed as a number
and represented by the symbol BHN, is computed as the ratio of the applied load in kg to the
spherical (surface) area of the indentation in sq.mm.
BHN  2P  P
 D[D  D 2  d 2 ]  Dt
where P is the Load in Kg or N, D is the diameter of the ball in mm., d is the diameter of
impression in mm and t is the depth of indentation in mm. BHN is expressed in N/mm 2.The
Brinell test is not suitable for extremely hard materials, because the ball itself would deform too
much. It is not adopted for use with case hardened surfaces, because the depth of indentation
may be greater than the thickness of the case and the soft case below will start yielding. The
specimen surface must be flat & reasonably well polished.
In order to obtain an impression of reasonable size, the following ratio of P/D2 may be used.
2
S. No Material P/D Approximate BHN
1 Copper, Aluminum and Brass 5 20-60
2 Alloys of Brass and Aluminum 10 60-160
3 Steel and Cast Iron 30 Above 160

4) Procedure
 Place the specimen on the anvil so that its surface will be normal to the direction of the
applied load.
 Raise the anvil by means of the star hand wheel until the specimen just makes contact with
the ball. In some testing machines electrical signals (on-off) will indicate its position.
 Apply the load by means of the hand lever. Initially, the hand lever for applying the load will be
away from the observer. Now, turn the lever towards the observer, so that the entire load is
applied on the specimen.
 Maintain the full load for the prescribed time. (It should be noted that the self weight of the pan
+ weight of hanger + minor load of 187.5 kg is equal to 250 kg and should be included while
placing the required number of weights in the pan).
 Release the load by turning the hand lever away from the observer & remove the specimen by
lowering the specimen.
 Measure the diameter d of the indentation (impression) made on the specimen using a
travelling microscope or micrometer microscope.
 Make at least three independent hardness determination on each specimen and take the
average value.
5) OBSERVATIONS:
Calculation of BHN
S. Material Dia. of the indenter Dia. of ball indenter Applied Load BHN
No d (mm) D (mm) (Kgf)
6) RESULT: Brinell hardness number of the given material is _________ BHN

EXPERIMENTAL METHODOLOGY 4.5 (B) ROCKWELL’S HARDNESS TEST
ROCKWELL’S HARDNESS TEST
1) Description:
Rockwell’s Hardness Testing Machine:
The machine consists of a dial gauge with red and black scales. A long pointer and short pointer with
the indication are contained in the machine. Red scale is used for reading obtained with ball
indenter and black scale is used for diamond indenter. Symbols B and C apply with major load 100
and 150 Kgs respectively. For both these scales the minor load is 10 Kg. the major loads being 90 and
140 kg respectively.
Tools Required:
A) Emery paper
B) Indenters: ball indenter of 1.5875 mm made of tungsten carbide or hardened steel. The
diamond indenter is having 0.2 mm radius tip with an apex angle of 1200
Method Of Application Of Load:
The standard test shall be carried out by selecting proper scale, load and penetrator. The minor
load shall be applied gradually and progressively to the specimen in a direction normal to its
surface and axially to the penetration without removing the minor load, and the position of
specimen undisturbed, the major load shall then be additionally applied gradually and
progressively in 4 to 5 seconds. As soon as the reading of the indicator becomes steady, the
major load shall be gently removed, the minor load being retained and the test specimen
remaining undisturbed.
2) Diagram

3) Theory:
Hardness may be defined as resistance to penetration or resistance to abrasion. The test

involves in determining the depth of impression caused by the penetration of certain standard
loads on the specimen. The following are the various methods of hardness tests available
1) ROCKWELL ‘S DIRECT READING HARDNESS TEST

2) BRINNELL’S HARDNESS TEST
3) VICKER’S HARDNESS TEST
Out of the above tests, Rockwell hardness test is more extensively used in all engineering
applications because of its simple testing procedure, lack of in-depth calculations, direct reading
across of hardness number etc.
The principle is introduced by Stanley Rockwell in 1919. The principle consists in
application of a some initial load to the penetrator to eliminate any effect due to surface
imperfections the major load is then added to the depth of penetration produced by the total
load is taken as a measure of hardness. The reading is inversely proportional to the depth of
penetration so that the greater penetration, the lower hardness number and vice-versa.
The most common scales used are A, B and C.

4) Procedure:
 Place the semi polished specimen on the platform.

 Insert the diamond cone indenter for C scales and 1/16” steel ball for B scale inside the
sleeve and tighten the screw. Check that there is no movement of indenter.
 Set the required load (150Kg for C scale and 100Kg for B scale) by turning the knob provided
by the side of the machine.
 Bring the specimen into contact with the indenter by rotating the elevating screw by
rotating the star handle. By further elevating the specimen, the minor load of 10Kg is
applied such that pointer indicates ‘x’ on the smaller graduated arc scale and the longer
pointer indicates on the outer C scale and 30 on the inner B scale.
 Now turn the lever away from the observer slowly. The longer pointer moves away and
when it comes to rest, wait 8 to 10 sec for the entire application of major load.
 Now turn the lever slowly to the observer i.e. to the original position. Now the entire load is
being lifted off from the specimen.
 Now the longer pointer moves back and when it comes to a rest position, note the reading
on the outer black dial(C scale) and on the inner red dial(B scale)
 The reading on the dial indicates directly hardness number (RHN) which is dimensionless.
 A minimum of 3 trial readings are taken at separate location on the surface of the specimen.
The average value of these 3 readings gives the true Rockwell hardenings number which is
reported as HRC and HRB for Rockwell in C scale and Rockwell in B scale respectively.
5) Observations:
TYPE OF STD. LOAD IN KG HARDNESS HRC/ HRB

S NO MATERIAL INDENTOR MAJOR MINOR T1 T2 T3 AVERAGE
6) Result: Rockwell Hardness Number of the given material is _________ RHN

7) Precautions:
 In every case the final movement of the hand wheel is to raise elevating screw, never to
lower it.
 Before starting a test, one or two preliminary tests shall be made whose readings shall be
discarded so as to eliminate the errors due to the sluggishness of spring inside the machine.
 As both Diamond and Ball indenters are liable for deformation, they should check from time
to time.

4.6 EXPERIMENTAL METHODOLOGY TORSION TEST ON SPRINGS
TORSION TEST ON SPRINGS

1) Description:
The spring testing machine consists of steel frame in which spring is fixed. Both the ends
of the spring is fixed to the frame by using bolt and nut in tension test and the spring is placed
between the two jaws in compression test. The load is applied through the lever by pressuring
the oil which moves the jaws up and down. The deflection of the spring is measure on the scale
attached to the vertical column.
2) Diagram:
3) Theory:
Springs are elastic member which distort under load and regain their original shape
when load is removed. They are used in railway carriages, motor cars, scooters, motorcycles,
rickshaws, governors etc. According to their uses the springs perform the following Functions:
 To absorb shock or impact loading as in carriage springs.

 To store energy as in clock springs.
 To apply forces to and to control motions as in brakes and clutches.
 To measure forces as in spring balances.

To change the variations characteristic of a member as in flexible mounting of motors.

The spring is usually made of either high carbon steel (0.7 to 1.0%) or medium carbon alloy
steels. Phosphor bronze, brass, 18/8 stainless steel and Monel and other metal alloys are used
for corrosion resistance spring. Several types of springs are available for different applications.
Springs may classified as helical springs, leaf springs and flat springs depending upon their
shape. They are fabricated of high shear strength materials such as high carbon alloy steels
spring form elements of not only mechanical system but also structural system. In several cases
it is essential to idealize complex structural systems by suitable spring.
4) Procedure (For Tension Test):

 Measure the outer diameter (D) and diameter of the spring coil (d) for the given
compression spring by using vernier caliper
 Count the number of turns i.e. coils (n) in the given spring.
 Place the spring between upper and middle jaws by using bolt and nut.
 Insert the spring in the spring testing machine and load the spring by a suitable
weight and note the corresponding axial deflection in tension.
 Note down the initial reading from the scale in the machine.
 Increase the load and take the corresponding axial deflection readings.
 Find the actual deflection of the spring for each load by deducting the initial scale
reading from the corresponding scale reading.
 Calculate the modulus of rigidity for each load applied.
 Plot a curve between load and deflection. The shape of the curve gives the stiffness
of the spring.
(b) Observations Table (For Tension Test)
S.No. Load (W) Deflection ∆ Stiffness of Modulus of Rigidity

In KN (in mm) Spring=W/∆ ‘N’
(N/m) (N/mm2)
1
2
3
4
5
6

(C) Calculations :
Least count of vernier : mm

Mean dia of coil wire (d): mm
Mean radius of Spring (R): mm
No. of coils (n):
64WR 3n
Deflection of Helical Spring, 
Nd 4
64WR 3n
Rigidity modulus of spring, N=
d 4
5) Procedure (For Compression Test):

 Measure the outer diameter (D) and diameter of the spring coil (d) for the given
compression spring by using vernier caliper
 Count the number of turns i.e. coils (n) in the given compression specimen.
 Place the compression spring at the center of the bottom beam of the spring testing
machine.
 Load the spring by a suitable weight and note the corresponding axial deflection in
compression.
 Note down the initial reading from the scale in the machine.
 Increase the load and take the corresponding axial deflection readings.
 Find the actual deflection of the spring for each load by deducting the initial scale
reading from the corresponding scale reading.
 Calculate the modulus of rigidity for each load applied.
 Plot a curve between load and deflection. The shape of the curve gives the stiffness
of the spring.

(b) Observations Table (For Compression Test)
S.No. Load (W) Deflection ∆ Stiffness of Modulus of Rigidity

In KN (in mm) Spring=W/∆ ‘N’
(N/m) (N/mm2)
1
2
3
4
5
6
(c) Calculations :
Least count of vernier : mm

Mean dia of coil wire (d) : mm
Mean radius of Spring (R): mm
No. of coils (n) :
64WR 3n
Deflection of Helical Spring , 
Nd 4
64WR 3n
Rigidity modulus of Spring , N=
d 4

6) Graphs:
Load vs Deflection
Load
Deflection

EXPERIMENTAL METHODOLOGY 4.7 DEFLECTION TEST ON SIMPLY SUPPORTED BEAM
DEFLECTION TEST ON SIMPLY SUPPORTED BEAM
1) Description:
Deflection at any point on the axis of the beam is the distance between its position
before and after loading. Slope at any section in a deflected beam is defined as the angle in
radians which the tangent at the section makes with the original axis of the beam
2) Theory:
 If the beam is supports 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 original position of the beam is called deflection.
 When a simply supported beam subjected to point load at the midpoint, the beam bends
concave upwards.
Beam :
Beam is a structural member used for bearing loads. It is typically used for resisting
vertical loads, shear forces and bending moments.
Based on support, beams can be classified as:

 Simply supported beam
 Cantilever beam
 Overhanging beam
 Continuous beam
 Fixed beam
Simply supported beam:
A simply supported beam is a type of beam that has pinned support at one end and roller
support at the other end. Depending on the load applied, it undergoes shearing and bending. It is
the one of the simplest structural elements in existence.

Cantilever beam:
A cantilever beam is fixed at one end and free at other end. It can be seen in the image
below.
Overhanging beam:
A overhanging beam is a beam that has one or both end portions extending beyond its
supports. It may have any number of supports. If viewed in a different perspective, it appears as if
it is has the features of simply supported beam and cantilever beam..
3) Experimental Setup:

Schematic diagram of simply supported beam
Loads:
Any force that is transmitted to a body from another body by means of direct contact over an
area on the surface of the first body is a load due to body contact.
Concentrated Load (Point Load):-
This is a load whose area of contact is relatively small compared to the total area over the entire
length of the beam.
Distributed Load:-
This is a load whose area of contact is large relative to the length of the beam. Distributed loads
may further be classified as linearly varying or uniformly distributed loads depending on the manner in
which the load vary along the length of the beam.
Reactions:
As response to applied loads, the beam and the supports react by an internal force which is
opposite to the applied loads in order to remain in equilibrium. The reactions at the supports give rise to
an internal shear force which acts at every section of the beam. To maintain its equilibrium, the beam
reacts to turning effect of external loads in form of internal bending moments which vary along the
position of the beam.
Deflection:
In deformed position; the axis of the beam which was initially in a straight longitudinal line
assumes some particular shape which is called deflection curve. The vertical distance between a point in
neutral axis and corresponding a point in the deflection curve is called deflection at that point.
Reasons For Beam Deflect:
It is reasonable to deduce that the amount a beam will deflect is based on 4 things:
 Load on the beam (Force)
 Distance between the beam’s supports (Length)
 Material the beam is made of (Material)
 Shape of the beam (Geometry)

Mathematical Expression For Deflection Of Simple Supported Beam:
The deflection at mid point is given by
WL3
δ=
48EI
Here, W is the Load acting on the simply supported beam at centre, kg
L is the Length of the beam between the supports, mm
N
E is the Young’s modulus of material of the beam,
mm 2
I is the Second moment of area of the cross- section (i.e, moment of Inertia) of the
beam, about the neutral axis, mm4
bd 3
I=
12
Where,
‘b’ is the width of the beam and
‘d’ is the depth of the beam.
From the above equation,
WL3
E=
48δI
4) Procedure:
 Place the beam on knife edge supports like simple supported model, and Take dimension
i.e., Length, Width, and measure the depth of the specimen using veriner calliper .
 Check the flatness of given beam with the help of dial gauge.
 Place the dial gauge under the beam where the deflection is to be measured.
 Place the hanger at the midpoints of the beam.
 Now place the weights in span in increasing order at mid point .
 Calculate the deflections in dial gauge for different weights.
 Repeat the experiment with various loads of the beams.
 Repeat the same procedure for both the materials (steel and wood) in longitudinal
(widthwise) and lateral directions (depthwise) of beam and also place the load

2L
at from right side support of the beam on longitudinal(Widthwise) and
3
lateral(depthwise) direction.
 Use the deflection equation to calculate the modulus of elasticity.
5) Calculations:
Least Count of callipers mm,
Least count of dial gauge mm,
Span of beam mm,
Total Depth of the beam mm,
Width of the beam mm,
FOR DEPTH OF THE BEAM:
S.no Main Scale reading V.C.R M.S.R+ (V.C.R  L.C)
Average

6) Observation Table:
L
For Steel and wood: Load placed   mid span of the beam on a longitudinal direction:
2
Young’s modulus
WL3
S.No Load ,W 48δI
(in kg ) Mild
Steel
1
2
3
4
5
6
7
8
9
10
7) Precautions:
 Make sure that beam and load are placed a proper position.
 The cross- section of the beam should be large.
 Note down the readings of the vernier scale carefully.
8) Result :
Deflection of the Beam:

EXPERIMENTAL METHODOLOGY 4.8 STUDY OF MICROSTURCTURES OF METALS AND ALLOYS
STUDY OF MICROSTRUCTURE OF METALS AND ALLOYS
1) Description:
Abrasive Cut-Off Wheel Machine

 3 HP Motor, 1440 rpm
 Manual model.
 10” Diameter wheel
 Fully enclosed
 Cutting Capacity 50mm Diameter & 75mm Height X 200mm Length.
 This Equipment is used to cut the sample pieces form the component of all kind of
materials. These sample pieces can be used microscopic observation.
Belt Linishing Machine
This Equipment is used for rough Grinding of the Specimen.
Polishing Machine
 Variable speeds 100 rpm - 800rpm
 High torque PMDC motor with D. C. Drive.
 Water In and Drain
 Corrosion resistant fiber reinforced cover.
 8” Disc
 This Equipment is used to polish the specimen after rough grinding with the help of
polishing clothe. It also 2 useful for rough grinding with grinding disc
Metallurgical Microscope
 Binocular model Eye pieces: 10X, 15X & 2OX
 Magnification: 10X - 500X.
 This Microscope is used for microscopic observation of specimen with the adjustable
magnification.
CONSUMABLES / RAW MATERIAL
 Emery sheets (100grit,200,300,400,500,upto 1000)
 Polishing papers (1/0,2/0,3/0,4/0,6/0)
 sample pieces (brass, gray cast iron)
 etching agents for gray cast iron is a)ethanol 100ml b) nitric acid 6-10ml
 etching agents for Brass is a)ferric chloride 5ml b) Hcl acid 2ml c) ethyl alcohol 9ml
 aluminum powder.
Micro Structure Of Gray Cast-Iron & Brass:
BRASS GRAY CAST IRON

2) Theory:
Grey Cast Iron:
 In GREY CAST IRON carbon is always present in the form of graphite flakes
 2 .Grey cast iron has a characteristics grey appearance of the fracture and most of the castings
made today are grey cast iron castings
 Compositions grey cast iron always contains more carbon on silicon
 The tendency of carbon to form graphite flakes is due to increasing the carbon and silicon
content and decreasing the cooling rate
 The approximate compositions of grey cast iron is
 Carbon = 2.8 - 3.6%
 Silicon = 1.0 -2.75%
 Manganese = 0.4 – 1.0%
 Phosphorous = 0.1 -1.0%
 Sulphur = 0.06 -0.12%
Properties And Applications:
 GREY CAST IRON is fairly soft and readily machinable

 It has low melting point with good fluidity
 Low tensile strength , high compression strength and very little ductility
Composition Of Brass
 Brass is an alloy made primarily of copper and zinc.

 The proportions of the copper and zinc are varied to yield many different kinds of
brass.
 Basic modern brass is 67% copper and 33% zinc. However, the amount of copper may
range from 55% to 95% by weight, with the amount of zinc varying from 5% to 40%.
 Lead is commonly added to brass at a concentration of around 2%. The lead addition
improves the machinability of brass. However, significant lead leaching often occurs,
even in brass that contains a relatively low overall concentration of lead
Properties of Brass:
Brass often has a bright gold appearance; however, it can also be reddish-gold or
silvery-white. A higher percentage of copper yields a rosy tone, while more zinc makes the
alloy appear silver.
 Brass has a higher malleability than either bronze or zinc.

 Brass has desirable acoustic properties appropriate for use in musical instruments.
 The metal exhibits low friction.
 Brass is a soft metal that may be used in cases when a low chance of sparking is necessary.
 The alloy has a relatively low melting point.
 It's a good conductor of heat.
 Brass resists corrosion, including galvanic corrosion from salt water.

3) Procedure:
 Take the brass or gray cast iron specimen.
 Polish the specimen by using 100,220,320,400,500,600,and 1000 grade emery papers
 And then polish by 1/0, 2/0, 3/0, 4/0 and 6/0 polish papers for scratches free surface
 Wash the specimen by using water and then take the specimen to disc polishing
machine
 In disc polishing machine alumina powder is added with water and turn on the machine.
 Hold the Specimen tightly in the rotating disc for 4 minutes
 Disc polishing machine is used for proper mirror finishing surface
 Clean the specimen with alcohol and wash it under the stream of flowing water
 After washing the specimen let it to dry and then apply the suitable etchant agent for 30
to 60 sec
 After applying etchant wash the specimen with stream of flowing water
 Dry the specimen with the help of air blower
 Place the specimen under the microscope for metallurgical studies.
 Draw the micro structure and identify the physical properties of the given specimen.
4) Observation:
s.no To be observed What is observed
1 Microstructure of given material
Structural characteristics of
2
materials
3 What kind of structure it has
5) Precautions:
 Polishing should be slow, sooth and flat.
 Uniform pressure is applied throughout the polishing.
 Check the grinding be done on the emery in one direction.
 Ensure mirror polishing surface.
 Etchants should be applied for a particular time and washed away.
 Care should be taken for polished surface.

Model Questions in M.T LAB (M-308)
1) Tension Test
a) Identify the components required for of Tension Test(LO)
b) Operate controller for moving jaws for of Tension Test (LO)
c) Fix job between UTM jaws by controller for of Tension Test (MO)
d) Operate Hydraulic pump of Tension Test (MO)
e) Note down readings of load and extensions from digital panel board of Tension
Test (HO)
f) Draw stress-strain curve of Tension Test (HO)
2) Compression Test
a) Identify the components required of Compression Test.(LO)
b) Measure the dimensions of a given concrete cube of Compression Test.(LO)
c) Connect the power supply and placing the specimen of Compression Test.(MO)
d) Operate the load valve and back oil valve of Compression Test.(MO)
e) Operate the load valve of Compression Test.(HO)
f) Observe the readings and noting of the final reading of Compression Test.(HO)
3) Shear Test
a) Identify the components required of Shear Test. (LO)
b) Check start and stop buttons, Opening and closing valves of Shear Test (MO).
c) Check the position of specimen in shear attachment of Shear Test (MO)
d) Measure the diameter of the specimen and fixing the Specimen in the Shear
attachment of Shear Test.(HO)
4) Impact Test (IZOD and CHARPY)

a) Identify the components required of Impact Test (Izod and Charpy).(LO)
b) Fix the one end of test specimen in jaws in Impact Test (Izod and Charpy).(MO)
c) Prepare the specimen with 450 notch for of Impact Test (Izod and Charpy) (HO)
d) Record the dial reading after releasing the hammer with and without test
specimen in Impact Test (Izod and Charpy).(HO)
5) Hardness Test
(i) Brinell’s Hardness Test
a) Identify the ball indenter and dial indicator in Brinell’s Hardness Test.(LO)
b) Operate the anvil in Brinell’s Hardness Test. (MO)
c) Measure the diameter (d) of the indentation in Brinell’s Hardness Test. (MO)
d) Load and Unload on specimen with use of hand lever in Brinell’s Hardness Test.
(HO)
e) Measure the diameter (d) of the indentation (impression) made on the specimen
using a micrometer microscope in Brinell’s Hardness Test.. (HO)
(ii) Rockwell Hardness Test
a) Identify the ball indenter and dial indicator of Rockwell Hardness Test.(LO)
b) Identify the load knob (or load hand lever) and loads changer indicator. (LO)
c) Load and Unload hand lever of Rockwell Hardness Test. (MO)
d) Load and Unload on specimen with use of hand lever of Rockwell Hardness Test.
(HO)
e) Measure the diameter (d) of the indentation (impression) made on the specimen
using a micrometer microscope. (HO)
6) Torsion Test
a) Identify the components required for Torsion Test.(LO)
b) Check load on the dial gauge in Torsion Test. (LO)
c) Set the spring between the two jaws by the movement of jaws
manually/hydraulically in Torsion Test .(MO)
d) Record dial gauge reading of load and Recording the deflection of the spring on
vertical scale in Torsion Test. (HO)
e) Adjust the load manually/hydraulically and record the dial gauge reading and
Recording the deflection of spring on the scale by increasing load in Torsion Test
(HO)
7) Flexural Test on Simply Supported Beam

a) Identify the components required in Simply Supported Beam. (LO)
b) Measure the length, width and depth of the given beam of Simply Supported
Beam(LO)
c) Adjust the dial pointer to bottom of the simply supported beam. (MO)
d) Record the dial gauge deflections to the corresponding loads of in Simply
Supported Beam . (HO)
e) Calculate moment of inertia and Young’s modulus of Simply Supported
beam.(HO)
8) Study of Micro Structure of Metals and Alloys

a) Order of apply emery papers in Study Of micro Structure of metals and alloys.(LO)
b) Apply Disc polishing method for fine finishing of specimen in Study Of micro
Structure of metals and alloys.(LO)
c) Sequence of polishing towards mirror finishing specimen in Study Of micro
Structure of metals and alloys.(MO)
d) Selection of etchants as per recommended in Study Of micro Structure of metals
and alloys.(HO)
e) Adjustment of microscope and observing the structure of specimen in Study Of
micro Structure of metals and alloys.(HO)

3-FDP-63-M-308-MT Lab-Total

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STATE BOARD OF TECHNICAL EDUCATION

& TRAINING::AP, VIJAYAWADA

DIPLOMA IN MECHANICAL ENGINEERING

1. Elastic limit 2. Yield strength 3. Ultimate strength

4. Young’s modulus of elasticity 5. Percentage of elongation 6. Percentage of reduction in area.

1. Universal testing machine (UTM) 2. Mild Steel specimen 3.Vernier caliper

NITTTR EXTENSION CENTRE-VIJAYAWADA

Category of Skill Sub Task

 Fixing job between UTM jaws by controller.

Sl. Time allocation

NITTTR EXTENSION CENTRE-VIJAYAWADA

5) Need And Scope:

NITTTR EXTENSION CENTRE-VIJAYAWADA

A) Measuring gauge length and

1. Identify the components required. (LO)

1) Which steel have tested ?

NITTTR EXTENSION CENTRE-VIJAYAWADA

1) Objective: To find the compressive strength of a concrete cube using CTM.

Category of Skill Sub Task

Handling of  Identifying the components required.

 Connecting the power supply and placing the specimen.

NITTTR EXTENSION CENTRE, VIJAYAWADA

Sl. Time allocation

 All loose clothing must be tucked in.

5) Need And Scope:

NITTTR EXTENSION CENTRE, VIJAYAWADA

6) Planning And Organisation :

1. Identify the components required.(LO)

NITTTR EXTENSION CENTRE, VIJAYAWADA

1. What is the purpose of compression test?

NITTTR EXTENSION CENTRE, VIJAYAWADA

1) UTM (Universal Testing machine)

Category of Skill Sub Task

Handling of ● Identifying the components required.

● Checking the power supply and working of UTM remote.

● Measuring the diameter of the specimen and fixing the Specimen in

NITTTR EXTENSION CENTRE, VIJAYAWADA (ECV)

5) Need And Scope Of The Experiment:

NITTTR EXTENSION CENTRE, VIJAYAWADA (ECV)

A) Measuring the diameter of the specimen

1. Identify the components required. (LO)

NITTTR EXTENSION CENTRE, VIJAYAWADA (ECV)

1. Distinguish between single shear and double shear?

2. Distinguish between average shear stress and maximum shear stress?

3. Why Modulus of rigidity is not determined from shear test?

4. Why structural component is designed mainly by considering double shear strength?

NITTTR EXTENSION CENTRE, VIJAYAWADA (ECV)

IMPACT TEST (IZOD and CHARPY)

1.Imapct testing machine

2. A mild steel standard test specimen.

i) Izod Impact Test

Category of Skill Sub Task

● Identifying the parts of Izod testing equipment.

● Fixing the one end of test specimen in jaws.

● Preparing the specimen with 450 notch.

NITTTR EXTENSION CENTRE, VIJAYAWADA

ii). Charpy Impact Test

Category of Skill Sub Task

● Identifying the components required.

● Fixing the two end of test specimen in jaws.

● Preparing the specimen with 450 notch.

4) Teaching points (IZOD and CHARPY IMPACT TEST):

Sl. Time allocation