TQM – mechanical properties

AGENDA
What means
Concepts
Total Quality Management
Testing methods
in steel production?
Tensile test

Test results

Summary

1
 TQM – mechanical properties
AGENDA

Concepts
TQM – mechanical properties
Testing methods

Tensile test

AGENDA

Mechanical properties- Basic concepts
Test results

Testing methods
Summary

Tensile test

Mechanical properties from tensile testing

2
 TQM – mechanical properties
AGENDA

Concepts
Mechanical properties
Testing methods Basic Concepts
Tensile test

Test results

Summary Definition of mechanical properties

=> How do materials respond to external loads

3
 TQM – mechanical properties
AGENDA

Concepts
Mechanical properties
Testing methods Types of loading

Tensile test

Test results

Summary

4
 TQM – mechanical properties
AGENDA

Concepts
Mechanical properties
Testing methods Stress and Strain
Tension and Compression
Tensile test

Engineering stress:
Test results
F is load applied perpendicular to the cross-
Summary section of the specimen, A0 is cross-sectional area
(perpendicular to the load) before application of
the load

Engineering strain:
Dl is change in length, l0 is the original length
Stress and strain are positive for tensile loads,
negative for compressive loads

5
 TQM – mechanical properties
AGENDA

Concepts
Mechanical properties
Testing methods Stress and Strain
Shear and Torsion
Tensile test

Shear stress:
Test results
F is load applied parallel to the upper and lower
Summary faces each of which has an area A0

Shear strain:
q is the strain angle

6
 TQM – mechanical properties
AGENDA

Concepts
Mechanical properties
Testing methods Stress – Strain behaviour

Tensile test

Test results

Summary

Materials subject to tension shrink laterally. Materials

subject to compression, bulge.

7
 TQM – mechanical properties
AGENDA

Concepts
Mechanical properties
Testing methods Stress – Strain behaviour

Tensile test

Elastic deformation
Test results
Reversible: When the
Summary stress is removed the
material returns to the
dimension it had before the
loading

Plastic deformation:
Irreversible: when the
stress is removed the
material does not return to
its previous dimension

8
 TQM – mechanical properties
AGENDA

Concepts
Testing methods
Testing methods Relaxation / Creep

Tensile test

Based on the various possibilities of external
Test results loading and the type of application different testing
methods for mechanical properties have been
Summary devised

A few examples:
external load is time-independent
=> relaxation / creep effects
=> mechanical property: creep strength
(important for pressure vessels,
chemical industry, oil and gas industry)

9
 TQM – mechanical properties
AGENDA

Concepts
Testing methods
Testing methods Wöhler- curve

Tensile test

External load is time-dependent (periodic)
Test results

Summary => effect of cyclic stress on material

=> mechanical property: fatigue strength
(important for civil engineering,
mechanical engineering)

10
 TQM – mechanical properties
AGENDA

Concepts
Testing methods
Testing methods Olsen or Erichsen Cup Test
3-dimensional quasi-static load
Tensile test

Test results

Summary

11
 TQM – mechanical properties
AGENDA

Concepts
Testing methods
Testing methods Olsen or Erichsen Cup Test

Tensile test

=> cup height at fracture point is measured

Test results
=> measures ability of material to withstand plastic
Summary deformation without rupture
=> mechanical property: ductility (D)
(important for sheet forming, deep drawing,
automotive industry)

12
 TQM – mechanical properties
AGENDA

Concepts
Testing methods
Testing methods Indentation test

Tensile test
=> small indenter (sphere, cone,
pyramid) is forced into
surface of material
Test results

=> size of indentation is

Summary measured
=> mechanical property:
hardness
(important for sheet
forming, automotive
industry)

13
 TQM – mechanical properties
AGENDA

Concepts
Testing methods
Testing methods
=> different hardness
testing methods, i.e.
Tensile test

Brinell (HB)
Test results
Rockwell (HRB)
Summary
Vickers (HV)
Knoop (HK) etc.

14
 TQM – mechanical properties
AGENDA

Concepts
Testing methods
Testing methods Hardness

Tensile test Brinell Hardness is

proportional to tensile
Test results
strength
But proportionality constant
Summary is different for different
materials
=> IMPOC
measurements
correlate with
Brinell hardness
measurements, not
with other hardness
measurements

15
 TQM – mechanical properties
AGENDA

Concepts
Testing methods
Testing methods Tensile Test
Uniaxial external quasi-static load
Tensile test
=> most commonly used sheet metal formability test
Test results
=> mechanical property: tensile strength
Summary => related tests:
=> Hot tensile test
important for steel applications at elevated
temperatures
=> High strain rate test
important for application where external load
changes rapidly with time

16
 TQM – mechanical properties
AGENDA

Concepts
Tensile test
Testing methods Test set up

Tensile test

Test results

Summary

17
 TQM – mechanical properties
AGENDA

Concepts
Tensile test
Testing methods Standardization

Tensile test => test result depend on sample preparation, test

execution (strain rate) and sample geometry
Test results

Summary

Strain rate in standard Tensile test: 10-3 /sec,

but strain rate in typical stamping is 101/sec ! 18
 TQM – mechanical properties
AGENDA

Concepts
Tensile test
Testing methods Standardization

Tensile test => therefore need for standardization

=> three major standardization systems worldwide
Test results
Europe (EN (DIN) Standard) (10 002)
Summary
USA (ASTM Standard) (ASTM A370)
Japan (JIS Standard) (JIS Z 2241)
=> within each system the sample geometry and the
test conditions are standardized

19
 TQM – mechanical properties
AGENDA

Concepts
Tensile test
Testing methods Standardization

Tensile test

Test results

Summary

Specimen dimensions according to DIN EN standard

20
 TQM – mechanical properties
AGENDA

Concepts
Tensile test
Testing methods Standardization

Tensile test

Test results

Summary

Specimen dimensions according to DIN EN standard

Specimen dimensions according to ASTM standard

21
 TQM – mechanical properties
AGENDA

Concepts
Test results
Testing methods Typical stress - strain diagram

Tensile test

Test results

Summary

Plastic deformation
Stress and strain are not proportional
The deformation is not reversible
22
 TQM – mechanical properties
AGENDA

Concepts
Tensile test results
Testing methods Mechanical properties derived from tensile testing

Tensile test => tensile strength (Rm), (TS)

=> yield strength (0,2% offset (Rp02), (YS)
Test results
or upper and lower Yield point (UYP, LYP, (ReH, ReL)
Summary => uniform elongation (Ag)
=> total elongation (A, (A80 for DIN-standard))
=> n-value (strain hardening exponent)
=> r-value (anisotropy values)
=> modulus of elasticity (E)
=> Ductility (D)
=> Toughness (T)

23
 TQM – mechanical properties
AGENDA

Concepts
Test results
Testing methods Tensile strength, TS, Rm [MPa]

Tensile test

Test results

Summary

24
 TQM – mechanical properties
AGENDA

Concepts
Test results
Testing methods Yield strength, YS, Rp02 [MPa]

Tensile test

Yield point P:
Test results
The strain deviates from
Summary being proportional to the
stress

Yield strength YS or Rp02

is chosen as that causing a
permanent strain of 0,2 %

25
 TQM – mechanical properties
AGENDA

Concepts
Test results
Testing methods Yield point, [MPa]

Tensile test

Test results

Summary
Some materials like low-
carbon steels show a
distinct lower and upper
yield point
(UYP, LYP, or ReL, ReH)

26
 TQM – mechanical properties
AGENDA

Concepts
Test results
Testing methods Elongation, Ag, A [%]

Tensile test

Ag:
Test results
Uniform
Summary elongation
=> Elongation
without change
in cross-section
A, (A80):
Total elongation

27
 TQM – mechanical properties
AGENDA

Concepts
Test results
Testing methods n - value (strain hardening exponent), [%]

Tensile test => is calculated from the uniform elongation Ag

Test results n = ln(Ag + 1)

=> n- value is a measure of the hardening of the
Summary
material during deformation
=> is a measure for the stretch-forming ability of the
material
=> the larger the n-value the more the material can
elongate before necking

28
 TQM – mechanical properties
AGENDA

Concepts
Test results
Testing methods r-value (anisotropy value)

Tensile test

Test results

Summary

b0: initial width

b1: width after
deformation
s0: initial thickness
s1: thickness after
deformation
29
 TQM – mechanical properties
AGENDA

Concepts
Test results
Testing methods r-value (anisotropy value)

Tensile test

Test results

Summary

r-value is a measure for the deep drawing ability of the material

Dr is a measure for the earing tendendy during deep drawing

30
 TQM – mechanical properties
AGENDA

Concepts
Test results
Testing methods r- value (anisotropy value)

Tensile test => r =1 : isotropic material

r >1: anisotropic material, under tensile loads
Test results
the material changes its width more
than its thickness
Summary
r <1: anisotropic material, under tensile loads
the material changes its thickness more
than its width
=> for deep drawing applications r should be more
than 1,25

31
 TQM – mechanical properties
AGENDA

Concepts
Test results
Testing methods Modulus of elasticity, E [MPa]
Elastic deformation
Tensile test

If the deformation is elastic

Test results
the stress-strain
relationship is called
Summary
Hooke’s law:

E is Young’s modulus or
modulus of elasticity
(Units [N/M2] = Pa)
Higher E means higher
”stiffness”

32
 TQM – mechanical properties
AGENDA

Concepts
Test results
Testing methods Ductility, D [%]

Tensile test => Ductility is a measure of

deformation at
Test results fracture

Summary

33
 TQM – mechanical properties
AGENDA

Concepts
Test results
Testing methods Toughness, T [J/m3]

Tensile test => Toughness is a measure

for the ability to absorb
Test results energy up to fracture = the
total area under the stress-
Summary strain curve up to fracture
=> Units: energy per unit
volume e.g. : J/m3

34
 TQM – mechanical properties
AGENDA

Concepts
Test results
Testing methods Typical Accuracies of tensile test

Tensile test => The measurement uncertainty is composed of the

individual measurement uncertainties, I.e. for the tensile
force, the measurement of the corresponding lengths and
Test results
thickness before and after the deformation.

Summary => Tensile test equipment is calibrated according to

precision classes
=> requires regular checks from an accretited Laboratory
=> test equipment is in a temperature controlled
environment
=> Typical testing equipment is calibrated according to
precision class 1
=> This results in an maximum measurement uncertainty of
not more than 2 % for the mechanical properties

35
 TQM – mechanical properties
AGENDA

Concepts
Test results
Testing methods Influence of Process parameters
on mechanical properties
Tensile test

Test results

Summary

36
 TQM – mechanical properties
AGENDA
Comparison with IMPOC
Concepts Mechanical Tensile test IMPOC Correlation with
property IMPOC

Testing methods Tensile strength, x x Yes

Rm
Tensile test Yield Point, x x Yes
Rp02, UYP, LYP
Test results Uniform x No
elongation,
Summary Ag,
Total elongation, x No
A, (A80)
n-value x No

r-value x No
Modulus of x No
elasticity, E
Ductility, D x No
Toughness, T x No
Hardness Yes, proportional
to Brinell value
37
 TQM – mechanical properties
AGENDA

Concepts
Summary
Testing methods Tensile test vs. IMPOC

Tensile test => The tensile test is more accurate than IMPOC-
measurements
Test results
=> The tensile test delivers more information about
the material than IMPOC
Summary
=> But all this information is only available after the
coil is produced, typically after a few hours
=> IMPOC delivers its information during production
=> IMPOC does not replace destructive testing, but it
reduces destructive testing to the necessary amount
=> IMPOC enables “Coil-refurbishment”

38
 TQM – mechanical properties
AGENDA

Concepts

Testing methods

Tensile test

Test results
Questions and Answers
Summary

For further information please refer to:

EMG Automation GmbH
ST – QS
Industriestraße 1
57482 Wenden
Germany
Phone: +49 2762 612 - 421
Fax: +49 2762 612 - 348
email: klaus.herrmann@emg-automation.com

39