Dept. of Industrial Engineering & Management Laboratory Manual

Department of Industrial Engineering and Management, R.V. College of Engineering, Bangalore 59.
Edition
2006
Dept. of Industrial Engineering & Management

Laboratory Manual
Material Testing lab Manual
Department of Industrial Engineering and Management
MATERIALTESTINGLAB
R.V. College of Engineering, Bangalore 59
MATERIALS TESTING LABORATORY
SCHEME OF CONDUCT AND EVALUATION
CLASS: III SEMESTER (New Scheme)
YEAR: 2006
Sl.
No
01
02
03
04
05
06
07
08
09
10
11
12
13
Expt.
No.
MT01
MT02
MT03
D01
MT04
MT05
MT06
D02
MT07
MT08
MT09
MT10
S01
S02
D03
SUBJECT CODE: MEL37 A

CLASS MARKS: 25
Title
CYCLE I
Tension Test on Mild Steel Specimen
Torsion Test on Mild Steel Specimen
Impact Tests (IZOD and CHARPY) on Mild Steel
Specimen
Non-Destructive Tests Demonstration
Rockwell hardness Test
CYCLE II
Wear Test
Double Shear Test on Mild Steel Specimen
Fatigue Test demonstration
Compression Test on Mild Steel Specimen
Brinell Hardness Test
CYCLE III
Vickers hardness Test
Bending Test on wood
Preparation of specimen for metallographic examination.
Microstructure study of the Engineering materials
identification
Heat treatment of steel materials & study of their hardness
using their Rock-well testing machine--Demonstration
TEST
TOTAL
KEY
MT Materials Testing Expt. S Study Expt. D Demonstration Expt.
No. of
Class
Class
& Test
Marks
01
01
20
20
01
20
01
20
01
10
01
20
01
01
20
20
01
01
10
20
01
10
01
10
01
13
50
250
EVALUATION SCHEME:
CLASS MARKS
(Reduced to 25)
= Class work total + Test Marks

10
Proposed by:
D.Venugopal setty.
Shobha N S
Prepared by:
H.M.Shadakshara
Approved by
Prof.K.S.Badarinarayana
SYLLABUS
MATERIALS TESTING LABORATORY
(Common to ME I IP I AU I IM I MA)
Sub Code MEL37 A/MEL47 A
IA Marks 25
Hrs/Week 03
Exam Hours 03
Total Hrs. 42
Exam Marks 50
PART-A
1. Preparation of specimen for metallographic examination of engineering materials and
study the microstructure of plain carbon steel, tool steel, gray C.I, SG iron, Brass, Bronze.
2. Heat treatment: Annealing normalizing hardening and tempering of steel & to study their
Rock-well hardness (Demonstration only)
PART-B
3. Conduction of tensile, shear, compression, torsion and bending tests of a Mild Steel
specimen using a Universal Testing Machine.
4. Conduction of Izod and Charpy tests on Mild Steel Specimen.
5. Experiment on Wear Study.
6. Brinell, Rockwell and Vicker's Hardness tests.
7; .Fatigue Test- (demonstration only).
8. Non-destructive test experiments - (demonstration only).
(a). Ultrasonic flaw detector
(b). Magnetic crack detector
(c). Dye penetrant testing
Scheme of Examination:
ONE question from part -A
(Identification only)
ONE question from part -B
Viva-Voce
10 Marks
:
:
30 Marks
10 Marks
INTRODUCTION:
Materials constitute an important component of the curriculum of every branch of
engineering and applied science. For fabrication of machines, manufacture of parts,
building of plants and structures, and carrying out processes, the choice of the material is
critical. An awareness of materials available to the characteristic material properties & us
are desirable for efficient problem solving, decision-making, and development of advanced
materials and functioning of an engineer. The need for materials literacy of engineers and
technologists is now recognized all over the world. It is clear that an engineer should keep
the materials scenario in mind while designing a component or machine. Otherwise his
design may become redundant. For the efficient design of engineering products, problem
solving, decision making and the overall efficient functioning of an engineer, an awareness
of available materials, there potentials and limitations, and an understanding of there
properties and behaviour or desirable.
Every engineering material is known by its set of properties. A variety of tests are
conducted in the Material Testing Laboratory to evaluate & compare the mechanical
properties of different materials.
The Mechanical Properties are:
1.
2.
3.
4.
5.
Stiffness
Elastic Strength
Yield Strength
Ductility
Malleability
6. Ultimate Tensile Strength

7. Fracture Strength
8. Stress
9. Strain
10. Toughness
These tests are classified into three categories:

1. Loading conditions
Static tests - Tension, compression, Torsion, Bending, Shear Tests
Dynamic testsImpact tests- Charpy Test, Izod Test
Repeated loading - Fatigue test.
High Temperature tests - Creep test
2. Hardness Tests
Penetration Tests - Rockwell Hardness Test, Brinell Hardness Test,
Vickers Hardness Test
3. Non- destructive Tests
Visual Inspection
Magnetic Particle inspection
Magnetic crack detector
Dye penetrate test
Radiography
Ultrasonic test
X-Ray test.
EXPERIMENT No. MT01
TENSION TEST ON DUCTILE MATERIAL

AIM: - To determine the strength and several properties of ductile steel, to observe the behaviour
of the material under load and to study the fracture and thus determine the following:
1.
2.
Yield strength
Tensile strength
3.
Ductility
i. Percentage elongation
ii. Percentage reduction in area
4.
Modulus of elasticity (Graphical Method)
APPARATUS / INSTRUMENTS / EQUIPMENT USED: 1.
Universal Testing machine
2.
Extensometer
3.
Vernier caliper
4.
scale
UNIVERSAL TESTING MACHINE
Equipment Description:UTM as name implies, are general purpose machines. They vary greatly in
physical size, load capacity, versatility & sophistication.
In its simplest form, a UTM system includes a load frame where the test is actually performed. The
load frame must, of course, be rugged enough for the application. Some means of control over the
load frame is necessary. This control can be as simple as hand wheel on a valve or as complex as a
computer to control the loading & unloading process and the rates at which these are done.
Generally a recorder is used to record permanently the results of the tests.
Grips or some other accessory are used to interphase between the sample being tested & the load
frame itself. The action & use of the grips is often one of the most critical and least understood
parts of the test.
Each UTM is desired to have a maximum load capacity. Small units may have a load of few 100N
or even less.
The UTM can be used for:
1. Tensile test
2. Shearing test
3. Compression test
4. Bending test
5. Functions of
i. Yield point
ii. Elasticity Modulus,
iii. Young's Modulus
iv. Ultimate value
v. Break value
PROCEDURE:1.
Determine the average cross-section of the given specimen. Scribe a
line along the bar and with a centre punch lightly mark a 120 mm gauge length symmetrical with
the length of the bar.
2.
Firmly grip the upper end of the specimen in the fixed head of the
testing machine using proper fixing devices or shackles. The specimen is placed such that the
punch marks face the front of the machine
3.
Firmly attach the extensometer to the specimen so that the axis
coincides with that of the specimen. Adjust the testing machine and extensometer to read zero. Grip
the lower end of the specimen taking care not to disturb the fixing of the extensometer.
4.
Select suitable increments of load (between 200 and 500 kgs) to obtain
at least 15 readings of strain within the proportional limit. Apply the load at a slow speed, taking
simultaneous observations of load and strain without stopping the machine. The extensometer is
used only till the yield point value is reached at which point the extensometer dial makes two
complete revolutions. After this, the elongation is observed on the scale fixed to the machine
frame.
5.
Loading is continued till the failure of the specimen. Record the
ultimate load and breaking load.
6.
Remove the broken specimen from the machine and observe the
failure characteristics. Measure the dimension of the smallest section. Hold the broken parts
together and measure the gauge length.
7.
Plot a stress-strain diagram and mark the following on the graph:
a. Upper yield point
b. Lower yield point
c. Breaking stress
d. Ultimate stress
8.
Calculate the slope of the graph (within the elastic limit), which is the
Youngs modulus value of the given material.
R.V. COLLEGE OF ENGINEERING, BANGALORE-560059
DEPARTMENT OF INDUSTRIAL ENGG. AND MANAGEMENT
MATERIAL TESTING LABORATORY
OBSERVATION / DATA SHEET
Date:
Lab : MT Lab
Name:
Class: III Sem
USN:
Expt.No:
Title of the Experiment: TENSION TEST

OBSERVATIONS:
Least count of extensometer =0.01mm
Least count of Vernier caliper = 0.02mm
DETAILS OF SPECIMEN:
Material
: Mild steel
Total length of specimen (L) :330mm
Length between shoulders (l) :133mm
Gauge length (l1)
:120mm
Diameter at the ends (D)
:19mm
Diameter of reduced section (d)
:14mm
Diameter of ruptured section (d1)
:8.5mm
Gauge length after fracture (l2)
:15.5mm
Shoulder
SKETCH OF THE SPECIMEN:
l1
l
L
Contd..
Signature of the staff in charge
Date:
Lab : MT Lab
Name:
Class: III Sem
USN:
Expt.No:
Title of the Experiment: TENSILE TEST

EXPERIMENTAL READINGS:
Extensometer Reading
Sl.
No
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Load
(Kg)
500
1000
1500
2000
2500
3000
3500
4000
4500
5000
5500
6000
6500
7000
Left
3
6
7
10
11.5
13
15
17
19
20.5
22.5
Right
Scale
reading
(mm)
0
0
1
3
4.5
6
8
9.5
11
13
16.5
Remarks
Yield point
1.5
3
4.5
15
16
17
18
19
20
7500
8000
8500
8000
6500
6000
6.5
9.5
13
35
39.5
40
Ultimate point
Breaking point

Date:
Lab : MT Lab
Name:
Class: III Sem
USN:
Expt.No:
Title of the Experiment: TENSILE TEST

Tabulated results:
Sl. Load
Extensometer Reading
No
(mm)
Left
Right Average
1
2
3
4
5
6
7
8
9
10
11
4905
9810
14715
19620
24525
29430
34335
39240
44145
49050
53955
12
13
14
15
16
58860
63765
68670
73575
78480
0.03
0.06
0.07
0.1
0.115
0.13
0.15
0.17
0.19
0.205
0.205
0
0
0.01
0.03
0.045
0.06
0.08
0.095
0.11
0.13
0.165
Scale
Reading
(mm)
0.015
0.03
0.04
0.065
0.08
0.095
0.115
0.1325
0.15
0.1675
0.195
1.5
3
4.5
6.5
9.5
Stress
(N/mm2)
Strain
31.86
63.73
95.59
127.46
159.32
191.19
223.05
254.92
286.78
318.65
350.51
0.00013
0.00025
0.00033
0.00054
0.00067
0.00079
0.00096
0.00110
0.00125
0.00140
0.00163
382.38
414.25
446.11
477.97
509.85
0.0125
0.025
0.0375
0.0542
0.07916
Remarks
Yield point
17
83385
13
541.70
0.1083
18
19
20
21
22
78480
73575
68670
63765
58860
35
36
37.5
39.5
40
509.85
477.97
466.11
414.25
382.38
0.2916
0.3083
0.3167
0.329
0.3334
Ultimate
point
Breaking
Point

Stress-Strain Diagram
600
stress(N/mm2)
500
400
300
200
100
0.
00
0
0. 13
00
0
0. 33
00
0
0. 67
00
0
0. 96
00
1
0. 25
00
16
3
0.
02
0. 5
05
4
0. 2
10
8
0. 3
30
83
0.
32
9
strain
SPECIMEN CALCULATION:
For Sl. No.3
1.Applied load , P = 1500 x 9.81 =14715 N
2.Area of cross section before fracture , A= d / 4 = x (14)2 /4 = 153.93 mm2
3.Area of cross section after fracture = d12 / 4 = x (8.5)2 /4 = 56.745 mm2
4.Applied stress = P / A = Load/ Initial area of cross section = 14715/153093
= 95.595 N/mm2 = 77.18 X106 N/m2
5. Strain = Change in length / Original length = 0.035/120= 0.000333

6. % Elongation = Change in gauge length X100 / Original gauge length
= (L2 -L1 )X 100 / L1 = (155-120)X100/120 = 29.17%
7. % Reduction in area = (Original area Area after fracture)X100 / Original area
= (153.93 56.745 )X100 / 153.93 = 63.135%
8.Yield strength = Load at yield point / Initial area of cross section = 5300*9.81/153.93
= 337.77 N/mm2 =3.377 X108 N/m2
9. Tensile strength = Maximum load / Initial area of cross section =
83385/153.93= 541.7 N/mm2 = 5.417 X108N/m2
10. Breaking strength = Load at break point / Initial area of cross section
= 58860/153.93=382.382 N/mm2 =3.823 X108 N/m2
11.Modulus of elasticity (Graphical), E = Slope of Graph = 2.4 X1011N/m2
RESULT :Experimental results are as follows:
Percentage elongation
= 29.166%
Percentage reduction in area
= 63.135%
Yield strength
= 3.377 X108 N/m2
Tensile strength
= 5.417 X108N/m2
Breaking strength
= 3.823 X108 N/m2
Modulus of elasticity (Graphical), E
= 2.4 X1011N/m2
EXPERIMENT No. MT02
TORSION TEST
AIM: - To determine the behaviour of ductile steel when subjected to torsion, and obtain the
following tensional properties:
Modulus of rigidity
Maximum Shear strength of the material
APPARATUS/EQUIPMENT/INSTRUMENTS USED
Torsion testing machine,

Torsion Shackles,
Vernier Calipers
TORSION TESTING MACHINE
Equipment
description:
Torsion Testing Machine is
designed for conducting
Torsion and Twist on
various metal wires, tubes,
sheet materials.
This Machine applies a
torque on the specimen held
in its chuck and measures
the twist.
Suitable for Torsion and
Twist test on various metal
rods and flats. Torque
measured by pendulum
dynamometer
system.
Geared motor to apply torque to specimen through gear box. Set of jaws to accommodate different
size
and
diameter
of
test
specimens
provided.

Date:
Lab : MT Lab
Name:
Class: III Sem
USN:
Expt.No:
Title of the Experiment: TORSION TEST

OBSERVATIONS:
Least count of the Vernier caliper =0.01mm
Least count of the Torque Indicator r=60Kg-cm
Least count Twist Indicator =0.5
TORQUE AND TWIST READINGS:
Sl.No.
TORQUE
Kg-Cm (x 60)
Twist (Degrees)
1
1.
10
2.
20
0.25
3.
12
30
0.75
4.
14
40
1.00
5.
15
50
1.25
6.
16
60
1.25
7.
17
70
1.25
PROCEDURE:1. Measure the dimensions of the specimen using Vernier caliper

2. Fix the specimen between the shackles. The axis of the specimen should coincide with the
axis of the shackles
3. Rotate the wheel very slowly to give a twist of 1=10
4. Note down the corresponding torque developed (kg-cm), T and the angle of twist, 2 from
the indicators.
5. Increase the twist 1 in steps of 10 till the failure of the specimen. Note the corresponding
values of 2 and T.
6. Calculate the effective twist, = 1 ~ 2
7. Calculate shear strength using formula, = T x R / J
8. Plot a graph between and .
9. Calculate rigidity modulus from the slope, G = Slope x L / R
TABULATION:
Torque
(division)
Torque
(N-m)
1
2
3
4
5
6
0
3
12
14
15
16
0
17.658
70.632
82.404
88.290
94.176
10
20
30
40
50
60
TWIST (Degree)
= 1 ~ 2
2
0
0.025
0.75
1.00
1.25
1.25
10.00
19.75
29.25
39.00
48.75
58.75
TWIST,
(radians)
Shear Stress,
(x108N/m2)
0.1745
0.3447
0.5105
0.6807
0.8508
1.0254
0
89.93
359.72
419.68
449.66
479.63
600
Shear Stress (x10 8 N/m )
Sl
No
500
400
300
200
100
0
0.1745
0.3447
0.5105
0.6807
Twist (Radians)
0.8508
1.0254
SPECIMEN CALCULATION (for sl.no.2)

1. Torque division = 3
Torque (T) = 3x60 Kg- Cm
T = 3x60x9.81/100 = 17.658 N m
2. Twist, = 1 ~ 2= 20 ~ 0.25 = 19.75 = 19.75 x /180 = 0.3447 radians
3. Diameter (D) = 10 mm,
Polar moment of inertia, J = D4 / 32
= (10)4 / 32 = 981.75 mm4 = 981.75 x10-12 m4
4. Shear stress,
= T x R /J = 17.658 x (5/1000)/ 981.75 X10-12 = 8.993 x107 N/m2
5. Maximum shear stress, max = 5.0961 x108 N/m2
6.
1. Modulus of rigidity or Polar Moment of Inertia, G = Slope x L / R N/m2
=(1.56x103x130)/5=4.056x109 N/m2
RESULTS: 1. Maximum shear stress
2. Modulus of rigidity
= 5.0961 x108 N/m2

= 4.056 x 109 N/m2
EXPERIMENT No. MT03
IMPACT TEST IZOD AND CHARPY

AIM:- To determine the relative impact resistance of a given specimen by conducting the IZOD
and Charpy tests.
APPARATUS / INSTRUMENTS / EQUIPMENT USED:
Impact testing machine,

Vernier caliper,
Centerpiece or setting gauge,
Allen key.
IMPACT- TESTING MACHINE
Theory: Impact loading differs from quasi-static loading. In that a load is applied over a very short
time instead of being introduced gradually at some constant rate. This causes significant changes in
the observed material properties from those associated with normal static tests. In the case of
impact loading the effects measured are of a dynamic nature, with vibration and possibly fracture
being observed.
The Notched Bar test, where specimens are subjected to axial, bending or torsion loads using
specialized testing machines. The technique involves swinging a weight of W from a certain
specified height h to strike the notched specimen, breaking it as it passes through, and arriving at a
height h', lower than the initial position of the pendulum.

The energy expended in rupturing the specimen can be described using the equation
U = W (h-h')
Where,
W= Weight
h & h= Specified height

Date:
Lab : MT Lab
Name:
Class: III Sem
USN:
Expt.No:
Title of the Experiment: IMPACT TEST--- IZOD

OBSERVATIONS:
Least count of Vernier Calliper:0.02mm
Least count of the Dial on the Impact testing machine = 0.1 kg-m
Dial Reading (Kg-m)
Material
Dimensions of the
specimen
Notch
angle
Initial
(E1)
Mild
Steel
Length = 27.0mm.
Diameter =12mm
Dia. of notch=9mm
Depth of notch =1.5mm
Width of notch = 3.0mm
45
1.5
Energy
consumed
(Kg-m)
1.5
Cast
Iron
Length = 25.0mm
Diameter = 11.0mm
Dia .of notch = 7.84mm
Depth of notch=1.58mm
Width of notch = 3.0mm
45
0.1
0.1
Final
(E2)
PROCEDURE: 1. Raise the pendulum and fix it to the pendulum notch. Place a thick wooden plank on the
stand below the pendulum pipe.
2. Keep the reading pointer at 17 kg-m on the inner scale. Release the Izod lever and allow
the pendulum to swing freely. Arrest the movement of the pendulum by using the
pendulum brake.
3. Record the indicator reading, which will give the energy lost due to friction and air drag.
See if the pointer comes to o (Zero) reading. If not, there will be on error (in calibration
of the instrument). Note that as initial reading. Again raise the pendulum and fix it onto the
notch.
4. Measure the lateral dimension of the specimen at the full section and at the notch and check
whether the dimensions conform to the given standard,
5. Now fix the Izod specimen inside the damping device, hold the specimen in hand vertically
such that the half of the V-notch is just above the horizontal surface of the clamping device
(cantilever beam position) and the notch is facing the pendulum.
6. Now insert the setting gauge such that the pointer edge of the setting gauge correctly fits
inside the V-groove. Simultaneously tighten the clamping screw using allen key and check
that there is no movement of the specimen.
7. After ascertaining that, there will be nobody in the range of swinging the pendulum.
8. Operate the Izod lever. Now the pendulum will swing freely and the specimen will be
smashed. Care must be taken to see that proper range is selected on the indicator (The
circular opening in the dial should be fully-3/4th red and partly black)
9. Stop the swinging pendulum by applying the pendulum brake.
10. Note the reading on the dial corresponding to the pointer.
11. Calculate the difference between final and initial readings. This value gives the impact
energy consumed or lost in breaking the specimen.
TABULATION AND CALCULATION:Material
Dial Reading
Energy
consumed
(E2- E1) (Kgm)
Energy
Consumed
(E2- E1) , J
Initial E1
(Kg-m)
Final E2
(Kg-m)
Mild Steel
1.5
1.5
14.715
Cast Iron
0.1
0.1
0.981
SPECIMEN CALCULATION (For Mild Steel):-
Actual energy absorbed by the specimen during fracture

= Energy recorded on the dial indicator with specimen in position - Energy recorded on the
dial indicator without specimen in position.
= 1.5- 0 = 1.5 Kg-m = 1.5x9.81 = 14.715 J
RESULTS:The actual energy absorbed by the specimens is as follows: 1. Mild steel = 14.715 J
2.Castiron = 0.981J

Date:
Lab : MT Lab
Name:
Class: III Sem
USN:
Expt.No:
Title of the Experiment: IMPACT TEST---CHARPY

OBSERVATIONS:
Least count of Vernier Calliper:0.02mm
Least count of the Dial on the Impact testing machine =0.1Kgm
Material
Dimensions of the specimen
Notch
angle
Dial Reading
(Kg-m)
Initial
(E1)
Final
(E2)
Energy
consumed
Brass
Length = 60 mm
Breadth = 10 mm
Width of the notch=10mm
Depth of notch=02 mm
900
1.05
1.05
Mild
Steel
Length = 56.20 mm
Breadth = 9.76 mm
Width of the notch=10mm
Depth of notch=02 mm
900
3.8
3.8
RESULT :
DIMENSIONS OF SPECIMEN BEFORE TESTING
SL.
NO.
PARAMETERS
Length of the specimen (mm)
2
3
Breadth of the specimen (mm)

Thickness of the specimen (mm)
MATERIALS
BRASS
MILD STEEL
56.20
55.20
9.76
9.72
9.72
9.64
SPECIMEN CALCULATION
BRASS
Actual energy absorbed by specimen during fracture
= Energy recorded on the dial indicator with specimen in position - Energy recorded on
the dial indicator without specimen in position
= 1.05-0 = 1.05 kg-m = 1.05x9.81 = 10.30 N-m = 8.829 J
RESULTS:
The actual energy absorbed by the different specimens are as follows:Brass: - 10.3 J
Mild steal: -37.27 J
EXPERIMENT No. D01
NON -DESTRUCTIVE TESTS

INTRODUCTION: A Non - destructive test is an examination of a component in any manner which will not
impair its future use. Although non-destructive test do not provide a direct measurement of
mechanical properties, but they are very useful in revealing defects in components which could
impair their performance when put in service.
Non destructive tests make components more reliable, safe and economical.
ULTRASONIC TEST
AIM: To study the ultrasonic flaw detector and to determine the location of the interior crack or
cavity in the given specimen.
APPARATUS: Ultrasonic flaw detector.
THEORY: Ultrasonic flaw detector is a device, which is used to detect internal discontinuities in
the material by nondestructive means. It makes use of phenomenon of back reflection (echo) of
waves by surfaces. When ultrasonic waves are made to pass through the test material, portion of
the sound is immediately reflected from the surface at which they enter as a very large echo. Part
of the sound will continue on into the test material, until it is partially reflected from the back
surface as a second echo. If there is a discontinuity in the material, a portion of the sound will be
reflected from the discontinuity and will return to the receiver as a separate echo between the
echoes received from the front and back surface. The signals received are shown on a cathode ray
tube, which also has a time base connected to it, so that the position of the signal on the screen
gives an indication of the distance between the crystal generator and the surface from which the
echo originates.
Sound waves oscillating with a frequency greater than 20,000 cps are inaudible and are known as
ultrasound. High frequency sound is produced by a piezoelectric crystal, which is electrically
pulsed and then vibrates at its own natural frequency. In order to transmit the sound waves from
the crystal to the metal, it is necessary to provide a liquid couplant. This is accomplished by using
a film of oil between the crystal and the test piece. After the crystal has given off its short burst of
sound waves, it stops vibrating and listens for the returning echoes, i.e., one crystal probe is used
to send and receive the sound. This cycle of transmitting and then receiving is repeated at an
adjustable rate from 100 to 1000 times per second.
Returning echoes on the CRT causes short vertical spikes called pips. These are spaced along the
baseline according to their time of receipt. Since the sound travels through the material at a
constant speed, the spacing of the pips can be considered as indicating thickness. Selecting and
expanding full screen size of the CRT can eliminate unwanted echoes caused by reverberations
with the test piece.
PROCEDURE:
1. Clean the surface of the test piece.
2. Place the probe against the surface of test piece using thin oil film.
3. Switch on the power supply of the ultrasonic wave generator.
4. Adjust the number of cycles of transmitting and receiving the signals to the desired value.
5. Select the segment of time, which contain the echo pips.
6. Observe the echo from the cavity if any on the CRT and measure the relative distances of
pips on the time axis.
Let A = Time elapsed between the pips of front surface echo and bottom surface
echo (sec)
B = Time elapsed between the pips of front surface echo and cavity surface echo
(sec)
H = Thickness of test specimen (mm)
Location of the crack from the front surface x = (B/A)x h
ADVANTAGES:
1. It is a fast, reliable method of non destructive inspection
2. It is a very sensitive method.
3. The minimum flow size which can be detected is equal to about 0.1% of the distance from
the probe to the defect.
4. Big castings can be systematically scanned for initial detection of major defects.
5. Ultrasonic inspection involves low cost and high speed of operation.
6. The sensitivity of ultrasonic flow detection is extremely high, being at a maximum when
using waves of highest frequency.
LIMITATIONS:
1. Ultrasonic inspection is sensitive to surface roughness since cost surfaces are usually rough,
some preliminary machining an castings will be required.
2. In complex castings the interpretation of the oscillographic trace may not be easy. Waves
reflected from corners or other surfaces may give a false indication of defects.
APPLICATIONS:
1. Inspection of large castings and forgings, for internal soundness, before carrying out expensive
machining operations
2. Inspection of moving strip or plate (for laminations) as regards its thickness.
3. Routine inspection of locomotive axles and wheel pins for fatigue cracks.
4. Inspection of rails for bolt-hole breaks without dismantling railed assemblies.
MAGNETIC PARTICLE TEST

AIM: To detect the surface or subsurface crack of the given ferromagnetic material.
APPARATUS: Magnetic field generator and ferromagnetic powder.
Magnetic
particles
U-Horse Magnet
THEORY: The magnetic particle method of inspection

is aofprocedure
used to determine the
Location
Crack
presence of defects at or near the surface of the ferromagnetic objects. This method consists of
placing fine ferromagnetic particles on the surface. The particles can be applied either dry or in a
liquid carrier such as water or kerosene. When the part is magnetized with a magnetic field, a
discontinuity (defects) on the surface causes the particles to gather visibly around it. Thus, the
defects become a magnet due to the principle of flux leakage where magnetic field lines are
interrupted by the defect and collect the ferromagnetic particles. The collected particles generally
take the shape and size of the defects. Sub surface defects can also be detected by this method,
provided they are not deep. The ferromagnetic particles may be colored with pigments for better
visibility on the metal surfaces.
The magnetic fields can be generated either with direct current or alternating current, using yokes,
bars and coils. The equipment may be portable or stationery.
Procedure:
1. Clean the surface of the test specimen to remove scales, oil and grease.
2. Apply a thin layer of ferromagnetic particles over the surface to be tested.
3. Magnetize the test piece.
4. Observe the shape and size of the magnetic particles collected, which is the shape and size of
the defect.
VISUAL INSPECTION
Defects like surface cracks, tears, blowholes, metal penetration, rattails and buckles, swells, shifts,
surface roughness and shrinkage are easily located by visual inspection.
It is carried out with the marked eye or using a magnifying glass. This method is the simplest,
fastest and most commonly employed, but requires greater skill on the part of the inspector to
locate and identify different manufacturing defects.
The inspector identifies the casting defects and assigns their cause to some foundry operation or
raw materials so that corrective measures can be employed.
Visual inspection ensures that none of the features of a casting has been omitted or malformed by
moulding errors short running or mistakes in fitting.
LIQUID PENETRANT TEST

AIM: To detect the surface defects by penetrant test.
APPARATUS: Penetrant, developer and ultraviolet light source.
THEORY: In the liquid penetrant test, liquids are applied to the surface of the part and
allowed to penetrate into surface openings, cracks, seams and porosity. Two commonly known
types of liquid penetrants are:
(a)
Fluorescent Penetrants which fluoresce under ultraviolet light, and
(b)
surface.
Visible penetrant using dyes, usually red if which appear as bright outlines on the
The test piece is coated or socked in a liquid penetrant and the surplus coating is wiped off.
After a short time, a developing agent is added to allow the penetrant to seep back to the
surface (due to capillary action) and spread to the edges of openings. The surface is then
inspected for defects, either visually in the case of dye-penetrants or under ultraviolet light for
fluorescent penetrant. The developer includes dry powders, aqueous liquid and non-aqueous
liquid. This method is capable of detecting variety of surface defects and is used extensively.
PROCEDURE:
1. Clean the test piece surface to remove scales, oil and grease.
2. Immerse the test piece in the selected penetrant and hold it for some time.
3. Remove the excess penetrant on the test piece surface.
4. Apply the developer on the surface of the test piece.
5. Examine the surface of the test piece under appropriate viewing conditions.
6. Clean the surface to prevent corrosion, etc.
OTHER NON-DESTRUCTIVE TESTS
1. Hammer Test
2. Radiography Test
X- Ray radiography
Gamma-ray radiography
3. Testing for metal composition
-Wet analysis
- Spectroscopy
- Spot test techniques.
EXPERIMENT No. MT04
ROCKWELL HARDNESS TEST

AIM:- To determine the Rockwell hardness number of the given specimen.

APPARATUS / INSTRUMENTS / EQUIPMENT USED:
Rockwell Hardness tester

Indentors
ROCKWELL HARDNESS TESTER
Equipment Description: Rockwell HTM impacts a standard load on a steel ball or diamond
indenter.
Rockwell hardness test determines the hardness of ceramic substrates. The most common method
of calculating hardness of plastics such as nylon, polycarbonate, polystyrene, and acetal is done by
Rockwell hardness test. This test is also used for measuring the resistance of the plastic to
indentation. The dial gauge is used to calculate the difference in depth produced by two different
forces. The load applied, indenter diameter and the indentation depth can be measured using
Rockwell hardness value.

Date:
Lab : MT Lab
Name:
Class: III Sem
USN:
Expt.No:
Title of the Experiment: ROCKWELL HARDNESS TEST
OBSERVATIONS AND TABULATION

SL.NO
Material
Scale
Load(Kg)
Indenter
1
2
3
4
5
Mild steel
Cast Iron
Brass
Copper
Aluminium
C
C
B
B
B
150
150
100
100
100
Cone(120)
Cone(120)
Ball (1/16th
Ball (1/16th
Ball (1/16th
Rockwell Hardness Number

Trail 1
Trail 2 Trail 3
107
107
108
93
94
93
48
51
46
91
95
101
52
54
52
SELECTION OF LOAD AND INDENTOR

Scale
Symbol
Major Load
(Kg)
Indentor
Application
60
Cone
Cemented carbide, thin steel, hardened

steel.
100
(1/16) Ball
Copper alloys, Soft Steels, Aluminum

Alloys, Malleable Iron
150
Cone
Steel, Hard cast Iron, Paralyte malleable

Iron, Deep case hardened steel.
PROCEDURE
1. Place the specimen on the anvil.
2. Select the load and indentor combination based on specimen material.
3. Raise the anvil until the specimen comes in contact with the indentor. Continue to raise the
anvil slowly till the pilot lamp goes off. This indicates that the minor load of 10 kg is acting
on the indentor.
4. Actuate the lever to apply the major load.
5. Give at least 10 seconds after the lever comes to rest position.
6. Read the position of the pointer on the corresponding scale of the dial, which gives the
Rockwell hardness number.
7. Make three tests on each specimen.
8. Calculate average Rockwell hardness number.
9. Plot the bar chart separately for B-Scale and C-Scale
TABULATION AND CALCULATIONS:SL.

NO
Material
Scale
Load(Kg)
Indenter
1
2
Mild steel
Cast Iron
C
C
150
150
Brass
100
Copper
100
Cone(120)
Cone(120)
Ball dia
(1/16th of an
inch)
Ball dia
(1/16th
of an inch)
Ball
dia(1/16th
of an inch)
Aluminium
100
Rockwell Hardness Number

Trial
Trial 2 Trial 3 Avg.RHN
1
107
107
108
107.33
93
94
93
93.33
SPECIMEN CALCULATION:Material : BRASS

Scale : B-Scale
Indentor = 1/16 Ball Indentor
Major Load Applied = 100 Kgs
Rockwell Number for trail 1, RHN1 = 48
Average Rockwell Number = (RHN1+RHN2+ RHN3) / 3
= (48+51+46) / 3 = 48.33 Kg/cm2
RESULTS:MATERIAL
Cast Iron
Mild Steel
Brass
ROCKWELL HARDNESS
NUMBER
93.33
107.33
48.33
48
51
91
95
52
46
48.33
101
95.66
52
52.66
54
Copper
Aluminium
95.66
52.66
C Scale
Rockwell Hardness No.
110
107.33
105
100
93.33
95
90
85
Cast Iron
Mild Steel
Materials
B Scale
Rockwell Hardness No.
120
95.66
100
80
60
52.66
48.33
40
20
0
Brass
Copper
Materials
Aluminium
EXPERIMENT No. MT06
DOUBLE SHEAR TEST

AIM:- To conduct a Double shear test on different materials and obtain their shear strengths.
APPARATUS / EQUIPMENT / INSTRUMENTS USED: Universal testing machine,
Vernier calipers,
Double shear shackles.
UNIVERSAL TESTING MACHINE
DOUBLE SHEAR SHACKLES AND SPECIMEN:

Date:
Lab : MT Lab
Name:
Class: III Sem
USN:
Expt.No:
Title of the Experiment: DOUBLE SHEAR TEST

OBSERVATIONS:
Least count of vernier caliper =0.02mm
TABULATION
Sl.
No.
1
2
MATERIAL
DIAMETER (mm)
Failure Load (Kg)
Brass
Mild Steel
7.7
7.7
3200
4300
PRINCIPLE:
Shear stress is caused by forces which act parallel to in area if cross-section and tend to produce
sliding of one portion past another portion as shown in figure below:
If the force is resisted by failure through one plane and single area, then the material is said to be in
single shear. In single shear,
failure load
P
P
4P
= =
=
N / m2
2
2
area of cross section A D 4 D
=
Where,
D - initial diameter of the specimen.

P - failure load.
P
If 2 areas resist the fracture, then the area is said to be in double shear.
Failure Load
P
2P
=
=
N / m2
2
2 Area of cross section 2 A D
For conduction shear test, a suitable steel shackle may be fabricated based upon fork and eye plate
principle the specimen is inserted as a connecting pin in the bush housing between the shackles;
the fork plates of the shackle held rigidly together by bolts for avoiding any bending tendency of
the specimen under high loads, and is tested in double shear.
1. The diameter of the specimen is measured using vernier calipers and the area of cross
section of the specimen is calculated.
2. The specimen is than inserted inside the shear shackles & is placed inside the shear center
plate.
3. The entire assembly is then placed on the lower cross slide of the universal testing
machine.
4. The intermediate cross slide is then moved down till it makes contact with the top of the
centre plate, through which the load is applied on the specimen.
5. The machine is started and the load is applied gradually till the specimen fails. At this point
note down the load and the corresponding dial gauge reading.
OBSERVATION:
Sl.
MATERIAL
No.
1
Brass
2
Mild Steel
DIAMETER (mm)
Failure Load (Kg)
7.7
7.7
3200
4300
CALCULATION OF DOUBLE SHEAR STRENGTH

MILD STEEL
Area of cross section,
( 7.7 ) 2 = 46.566mm 2
d 2
A=
=
4
4
= 46.566 10 -6 m 2
Double strength,
Failure Load
4300 9.81
=
= 452.937 10 6 N / m 2
6
2 Area of cross section ( 2 46.566 10 )
BRASS
( 7.7 ) = 46.566mm 2
d 2
=
4
4
= 46.566 10 -6 m 2
2
Area of cross section,

Double strength,
A=
Failure Load
3200 9.81
=
= 337.069 10 6 N / m 2
6
2 Area of cross section ( 2 46.566 10 )
RESULT:
SL.N0
1
2
MATERIAL
DOUBLE SHEAR
STRENGTH
MILD STEEL
452.937 X106 N/m2
BRASS
337.0699 X106 N/m2
EXPERIMENT No. D02
FATIGUE TEST
AIM: To determine the fatigue limit and the fatigue strength.
APPARATUS: Fatigue testing machine and micrometer caliper.
THEORY: Failure due to repeatedly applied load is known as fatigue. The physical effect of a
repeated load on a material is different from the static load, failure always being brittle fracture
regardless of whether the material is brittle or ductile. Mostly fatigue failure occurs at stress well
below the static strength of the material. If the applied load changes from any magnitude in one
direction to the same magnitude in the opposite direction, the loading is termed completely
reversed, where as if the load changes from one magnitude to another (the direction does not
necessarily change), the load is said to be fluctuating load.
Fatigue testing machine: In the simplest type of machine for fatigue testing, the load applied is of
bending type. The test specimen may be of simply supported beam or a cantilever. R.R.Moore
rotating beam type machine for a simply supported beam.A specimen of circular cross-section is
held at its ends in special holders and loaded through two bearings equidistant from the center of
the span. Equal loads on these bearings are applied by means of weights that produce a uniform
bending moment in the specimen between the loaded bearings. A motor rotates the specimen.
Since the upper fibers of the rotating beam are always in compression while the lower fibers are in
tension, it is apparent that a complete cycle of reversed stress in all fibers of the beam is produced
during each revolution. A revolution counter is used to find the number of cycles the specimen is
repeatedly subjected to the load. For simply supported beam, maximum bending moment is at the
center.
The testing techniques are subjected to a series of identical specimens to loads of different
magnitudes and note the number of cycles N of stress (or load) necessary to fracture the specimen.
The data are plotted on a semi logarithmic paper, the stress S being plotted to a linear scale and the
number of cycles N to a logarithmic scale.This is known as stress-cycle (S-N) diagram and the
fatigue limit can be, determined from the diagram. Fatigue limit or endurance limit is the stress
below, which a material can be, stressed cyclically an indefinitely large number of times without
failure. The fatigue strength is the stress at which a metal fails by fatigue after a certain number of
cycles.
Specimens: All specimens should be taken from the same rod, each specimen should receive same
kind of machining and heat treatment. The specimens for tests have no sharp stress raisers. The
surface of the specimen is polished.
Fracture appearance: Under repeated loading, a small crack forms in a region of high-localized
stress, and a very high stress concentration accompanies the crack. As the load fluctuates, the
crack opens and closes and progresses across the section. Frequently this crack propagation
continues until there is in sufficient cross section left to carry the load and the member ruptures,
the failure being fatigue failure. Therefore fractured surface shows two surfaces of distinctly
different appearance.
1.
A smooth surface where the crack has spread slowly and the walls of the crack are polished
by repeated opening and closing. This surface usually shows characteristic of beach or clamshell
marking.
2. A crystalline or fibrous surface where sudden failure occurred.
PROCEDURE:
1.
Measure the diameter d and the length L of the specimen.
2.
Fasten the specimen in the chucks of the testing machine.
3.
Set the maximum load. Set the counter to zero, and start the machine.
4.
Note the number of cycles N the specimen experiences before fracture.
5.
Repeat the above test on the other specimens with gradually reduced loads. Draw the S-N
diagram and obtain the endurance limit.
EXPERIMENT No. MT10

BENDING TEST
AIM:- To conduct the bending test on the given material and there by determine the following:
i.
ii.
iii.
iv.
Stiffness
Maximum bending moment
Maximum bending stress at failure
Modulus of elasticity
Universal Testing Machine

Cathetometer
Bending test attachment
Former (acting as a knife edge to apply a concentrated load at the center of the specimen)
Cathetometer
The Cathetometer can measure with great precision the difference in level between two points
whether or not they lie on the same vertical line. This instrument is made of a robust graduated
vertical copper rod, more than a meter long. The rod turns on its axis and is mounted on a tripod
with leveling screws. Attached to the rod are two horizontal collimeter telescopes attached to
tracks which have a ruler and a pointer and which can slide along the rod. The instrument's case
has the form of a right angle prism and rests on a strong metallic tripod. Less sophisticated
cathetometers have one telescope with which the two points are collimated successively.
If two points, A and B, are collimated through the telescopes and the positions assumed by the two
pointers are read on the scale, the difference between gives the distance between the horizontal
planes of the two points. The collimation is effected by creating a coincidence between the image
of the point (observable through the telescopes) and the center of the instrument's optical grid. The
degree of precision obtained in measurement depends on the approximation obtained with the ruler
and on the care with which the graduated rod is put vertical and the telescopes horizontal.

Date:
Lab : MT Lab
Name:
Class: III Sem
USN:
Expt.No:
Title of the Experiment: BENDING TEST

OBSERVATIONS
Least count of vernier caliper = 0.02mm
Least of cathetometer = 0.01mm
MATERIAL SPECIFICATIONS
Length (l) mm
Breadth (b) mm
Thickness (d) mm
400
46
71
LOAD AND DEFLECTION READINGS

Cathetometer initial reading = 17.272mm
Sl. No Load (Kg)
MATERIAL: MATTI WOOD
Final Reading
Final-Initial Reading
1
0
17.272
0
2
300
17.403
0.131
3
600
17.413
0.141
4
900
17.413
0.141
5
1200
17.541
0.269
6
1500
17.788
0.516
7
1800
18.007
0.735
8
2100
18.126
0.854
9
2400
Breaking point

PRINCIPLE
A bending test can be performed on an actual being cross -section by using a 3-point loading
system. The bending fixture is supported on the platform of the hydraulic cylinder of the UTM ,
The loading edge is held in the middle or intermediate crosshead. At a particular load , the
deflection at the centre of the beam is determined using a dial gauge.
The deflection at the centre of the beam is given by
= W L 3 / (48 E I )
E = W L 3 / (48 I )
Stiffness , W/ = 48 EI/ L3
This is derived from the bending equation , M/I = / y = E/R
The beam with simply supported at two ends and loaded at the centre is as shown in figure
W
L/2
W/2
L/2
W/2
For the above beam

Maximum bending moment = WL/4
Since cross section of beam is rectangle with dimensions b&d,
I = bd3 / 12
Therefore, s = 3WL / (2d3) N/m2
Where L = Length of the specimen in meters,
b = breadth of the specimen in meters ,
d = depth or thickness of the specimen in meters ,
W= Applied load in N
PROCEDURE
1. The bending test attachment is fitted in the universal testing machine and the specimen is
fixed in it using the special shackles provided for the purpose.
2. The breadth and thickness of the specimen are measured using vernier caliper and its length
determined after fixing
3. The loading former is fixed in the intermediate cross head firmly and is adjusted till it just
touches the specimen.
4. Record the initial cathetometer reading .
5. Load is applied, and after every 300 Kg, the cathetometer is focused on the wood specimen
and the corresponding reading recorded.
6. Loading is continued till the specimen fails
7. Calculations are made.
8. A graph of load against deflection is plotted.
Principal features of supporting and loading devices for BEAM TESTS indicating provision
for longitudinal and lateral rotational adjustment at support
DEFLECTION MEASURING DEVICES
BENDING OF A BEAM
MATERIAL: TEAK WOOD

BENDING MOMENT CALCULATIONS
SL.
NO.
1
2
3
4
5
6
7
8
9
10
11
LOAD W
(X9.81 N)
0
300
600
900
1200
1500
1800
2100
2400
2700
3000
DEFLECTION READING (mm)

162.60
162.60
162.60
162.60
162.60
162.60
162.60
162.60
162.60
162.60
162.60
162.60
163.53
164.03
164.42
165.16
165.34
165.50
166.00
166.64
166.80
167.32
0
0.93
1.43
1.92
2.56
2.74
2.90
3.40
4.04
4.20
4.72
Bending
moment (N-m)
0
286.94
573.89
860.83
1147.77
1434.71
1721.66
2008.60
2295.54
2582.48
2869.43
MATERIAL : MATTI WOOD

BENDING MOMENT CALCULATIONS
1
2
3
DEFLECTION (mm)
LOAD W
(X9.81 N)
INITIAL
FINAL
0
300
600
17.272
17.272
17.272
17.272
17.403
17.413
= Final Initial
0
0.131
0.141
Bending moment
(N-m)
0
286.94
573.89
4
5
6
7
8
9
900
1200
1500
1800
2100
2400
17.272
17.272
17.272
17.272
17.272
17.272
17.413
17.541
17.788
18.007
18.126
Breaking
point
0.141
0.269
0.516
0.735
0.854
860.83
1147.77
1434.71
1721.66
2008.60
DEFELECTION vs LOAD GRAPH FOR TEAK WOOD

3500
LOAD (X9.81 N )
3000
2500
2000
1500
1000
500
0
0
0.93 1.43 1.92 2.56 2.74 2.9
3.4 4.04 4.2 4.72
DEFLECTION (X0.001 m)
LOAD (X9.81 N)
DEFLECTION vs LOAD FOR

MATTI WOOD
1600
1400
1200
1000
800
600
400
200
0
0
1.15
1.65
2.25
DEFLECTION (X0.001 m)
1.05
3.35
MATERIAL : TEAK WOOD (Sl. No. 2)
1. Deflection, = Final reading - Initial reading = (17.541-17.272)
=26.9 x 10-3 m
= 0.269 mm
2. Load, W = 1200 Kg = 1200 x 9.81= 11772 N

Length of the specimen, l = 400.0 mm = 0.4 m
Breadth of the specimen, b =47.0 mm = 0.47m
Thickness of the specimen, d = 71.0 mm = 0.071m
3. Bending moment, M = W l / 4 = 11772x 0.4 /4 = 1177.2 N-m
4 Maximum bending moment = Wmax x l /4
= 3000 x9.81 x 0.39/4 = 2869.43N-m
5 Momentum of inertia, I = bd3/12= 0.47 x (0.71 )3/12 = 1.4018 x 10-6 m4
6 Stiffness = W / = 2400 x 9.81/ 26.9 x 10 3 N/m
= 875.24 x 103 N/m
7 Maximum bending stress = 3 Wmax L/ ( 2 bd2 )
= 3 x 3000 x 9.81 x 0.4 / (2 x 0.071 x (0.047)2)
= 91.82 x 106 N/m2
8 From graph W vs ,
W = 2500x9.81 N = 3.9 x 10-3 m
Now,
Youngs Modulus, E = WL3 / (48 I )
= 4.28 x 1015 N/m2
RESULT :
SL.
No
1
2
3
4
PROPERTIES
Modulus of Elasticity
(Youngs Modulus) ( N/m2)
Maximum Bending (N-m)
Stiffness (N/M)
MATERIALS
TEAK WOOD
MATTI WOOD
9.95 x 109
2869.43
6.29 x 106
91.82 x 106
6.19 x 109
1397.93
4.04 x 106
44.17x106
CONCLUSION:
From above results, it can be concluded that
Teak Wood is having more strength than Matti Wood
EXPERIMENT No. MT08
BRINELL HARDNESS TEST

AIM:- To find out the Brinell Hardness Number for the given specimen/s of ferrous metals (mild
steel, cost iron) and non-ferrous metals (copper, Brass)
APPARATUS / EQUIPMENT/INSTRUMENTS USED: Brinell hardness testing machine ,
Ball Indentor
Traveling microscope .
Brinell Hardness Testing Machine
Equipment Description:Brinell HTM measures the resistance of a material to the penetration of a

hardened steel ball subjected to a standard load.
This Hardness Tester uses a machine to measure hardness by determining the depth of penetration
of a spherical shaped device under controlled conditions. A carbide sphere of a specified diameter
under a specified load is applied to the surface of the material and the diameter of the indentation is
measured. The diameter of the indentation made is measured with the aid of Microscope.
The Brinell hardness value is obtained by dividing the load to the actual surface area. This number
is used to make relative comparisons of the different materials.
The formula used to calculate the Brinell hardness number is as follows:
Brinell Hardness Number (BHN) = F/[/2 (D-D- Di)]

Where
F - Applied Load
D - Diameter of the spherical indenter
Di -Diameter of the resulting indenter impression
These machines are robustly built to provide laboratory accuracy in the harshest industrial
environments and are used all over the world. The only disadvantage is more time is consumed for
measuring hardness.

Date:
Lab : MT Lab
Name:
Class: III Sem
USN:
Expt.No:
Title of the Experiment: BRINELL HARDNESS TEST

OBSERVATIONS:
Diameter of ball indenter =2.5mm
Least count of micrometer =0.001mm
TABULATION:
Sl.
No.
1
2
3
4
MATERIAL
Steel
Cast Iron
Brass
Copper
LOAD
Duration of
Diameter of
(KG)
187.5
187.5
62.5
62.5
loading (sec)
15
15
15
15
indentation(mm)
1.117
1.255
1.247
1.043
1.031
1.045
0.82
0.812
0.831
0.965
0.955
0.975
DERIVATION FOR BRINELL HARDNESS NUMBER

The principle of the Brinell Hardness Number is as shown in Figure .
From the geometry of the figure,
h = depth of indentation in mm
d = diameter of indentation in mm
D = diameter of indentor ball in mm
O
From triangle OAE,

OA =Sqrt ( OE2 EA2)
= Sqrt[( D/2)2 (d/2)2]
h = OB- OA
= D/2 - Sqrt[( D/2)2 (d/2)2]
Area of spherical indentation,
D/2
C
D/2
E
h
B
d
A = P x DXh=P x Dx{D/2 - Sqrt[( D/2)2 (d/2)2]}

= P x (D/2) x{ D - Sqrt[( D)2 (d)2]}
BHN = Load / Area of spherical indentation
=
P
P x (D/2) x[( D Sqrt [( D)2 (d)2]
Cross Sections of Indentation in Brinell Test
PROCEDURE:
1. Place the polished specimen on the platform.
2. Raise the platform till the surface of the specimen gets focused on the microscope screen.
3. Select the load by pressing the load selector.

Load P : 30XD2 for ferrous materials
:10 D2 For non ferrous materials
: 5 D2 for soft metals and alloys
Where P is the load in kg. and
D is the diameter of the indentor in mm.
4 Press the actuator in position,then the load acts on the indentor.
5. Wait till the handle on the left side of the frame comes to rest position. Now allow the load to
act for 15 seconds for ferrous materials and 30 seconds for non ferrous materials.
6. Press the handle down without jerk to release the load and to bring the objective lens back into
position
7. Measure the diameter of the indentation using the micrometer and microscope
8. For each materials make at least three indentations and measure the diameters.
9. Calculate the BHN for each diameter obtained and take the average of the three.
10. Tabulate the results.
11. Draw the Bar chart
TABULATION AND CALCULATIONS
Sl
No
1
2
3
4
Material
Load
(Kg)
COPPER
BRASS
MILD STEEL
CAST IRON
62.5
62.5
187.5
187.5
Duration Of
Loading
(Sec)
30
30
15
15
Diameter of Indentation
(mm)
0.965
0.82
1.117
1.043
0.955
0.812
1.255
1.031
0.975
0.831
1.247
1.045
Average
BHN
(X108N/M2)
8.05
11.478
15.394
21.112
MATERIAL : COPPER
Applied Load, P = 62.5 Kg.
Diameter of Ball, D = 2.5 mm
Avg.Diameter of Indentation, d= 0.965 mm
BHN = P / [ x (D/2) x (D- Sqrt D2 d2)]
= 62.5 / [ x(2.5/2)x(2.5 Sqrt (2.5)2 (0.965)2)]
= 82.143Kg / mm2 = 82.143x9.81 N /mm2 = 8.05 x 108 N/m2
RESULT:
1. Bar chart was drawn for the given materials
2. The BHNs of the given materials are as shown in below:
MATERIAL
1
2
3
4
COPPER
BRASS
MILD STEEL
CAST IRON
Brinell Hardness Number
SL.
NO
BRINELL HARDNESS
NUMBER
(X108N/ m2)
8.05
11.478
15.394
21.112
25
21.112
20
15.394
15
10
11.478
8.05
5
0
COPPER
BRASS
MILD
STEEL
Materials
CAST IRON
EXPERIMENT No. MT09
VICKERS HARDNESS TEST

AIM: - To determine the Vickers Hardness number of the given material
APPARATUS/EQUIPMENT/INSTRUMENTS USED:
Vickers Hardness Tester,
Diamond pyramid indentor.

Vickers Hardness Testing Machine
Vickers HTM is used to measure hardness of metals with hard surfaces. It is measured from the
size of an impression produced under standard load by a diamond indenter used, which is pyramidshaped. The diagonal length is measured with a Microscope. The formula used to calculate the
Vickers Hardness Number is as follows:
Vicker Number (HV) = 1.854(F/ D)
Where,
F - Applied Load,
D - Indentation Area
Advantages of Vickers Hardness Tester

The diagonal of the square can be measured easily and accurately Easier method for testing harder
materials.
Disadvantages of Vickers Hardness Tester
More Complicated & Expensive

Date:
Lab : MT Lab
Name:
Class: III Sem
USN:
Expt.No:
Title of the Experiment: VICKERS HARDNESS TEST

OBSERVATIONS:
Indentor = Square pyramid indentor
Least count of traveling micrometer =0.001mm
TABULATIONS
Sl. No.
1
2
3
4
1
MATERIAL
BRASS
CAST IRON
MILD STEEL
COPPER
BRASS
Standard
Load P
(Kg)
20
30
30
20
20
Diagonal width (mm)

d1
0.500
0.501
0.618
0.569
0.500
0.500
0.530
0.610
0.553
0.500
d2
0.486
0.544
0.625
0.558
0.486
0.500
0.559
0.618
0.547
0.500
0.467
0.516
0.620
0.547
0.467
0.500
0.539
0.613
0.548
0.500
THEORY :Vickers hardness number indicate the extent of resistance offered by the material to permanent
indentation under static loading .
The test consists in forcing a square based diamond pyramid (with an angle of 136 0 between
opposite faces) into the ground or polished surface to be tested. The pyramidal indentor makes
impressions that remain geometrically similar irrespective of its size.
The hardness number is derived from the relationship between the applied load and the surface
area of the indentation.
Definition: Vickers hardness number is defined as the ratio between load and surface area of the
impression and is calculated by formula,
Vickers hardness number (VHN) = 2 P sin (q/2)/ d2
= (1.854xP/d2) Kg/mm2
=(18.188 x 106 x P/d2) /m2
Where P = applied load in kg
d = Length of diagonal of indentation in m
= apex angle of the pyramidal indentor
PRINCIPLE :-
Diamond pyramid Indentor

(included angle 1360 )
d2
d1
Top view of indentation
PROCEDURE:1. Place the polished specimen on the platform

2. Raise the platform till the surface of the specimen is focused on the microscope screen.
3. Select the load by pressing the load selector button
4. Load , P = 30 Kg, For ferrous materials
5. = 20 Kg. For non-ferrous materials
6. Wait till the handle on the left side of the frame comes to rest position, and after that
allow the load to act for 15 seconds for ferrous materials and 30 seconds for non-ferrous
materials
7. Press the handle down without any jerk to release the load and to bring the objective lens
back into the position
8. Measure the length of the diagonals (d1 and d2) using the traveling micrometer and
calculate their average, d.
9. For each material make at least three indentations and measure the length of the diagonals
10. Using the formula, calculate the Vickers hardness number for each trial and calculate their
average.
Sl.
No.
TABULATION AND CALCULATIONS

MATERIAL Load
Length of diagonal (mm)
(Kg)
d1
d2
d=(d1+d2) / 2
VHN X106
N/m2
Average
VHNX106
N/m2
1493.04
BRASS
20
0.500
0.500
0.486
0.500
0.476
0.500
0.500
0.488
0.493
1455.02
1527.46
1496.65
COPPER
20
0.569
0.553
0.558
0.547
0.547
0.548
0.558
0.550
0.553
1168.26
1202.49
1189.48
1186.74
CAST IRON
30
0.541
0.530
0.544
0.559
0.516
0.539
0.550
0.523
0.542
1803.74
1994.79
1857.38
1885.3
MILD STEEL
30
0.618
0.610
0.625
0.618
0.620
0.613
0.618
0.615
0.619
1428.64
1442.61
1424.03
1431.76
Material : Brass
Load,P = 20 Kg = 20 x 9.81 N = 196. 2 N
For Trial 1,
Length of diagonals, d1 = 0.500 mm & d2 = 0.500 mm

Average length of diagonal, d = (d1 +d2)/2 = (0.500 +0.500)/2
= 0.500 mm = 0.500 x 10- 3 m
VHN1 = (18.188 x 20)/ (0.500 x 10- 3 ) 2 = 1455.02 x 106 N/m2
VHN2 = (18.188 x 20)/ (0.488 x 10- 3 ) 2 = 1527.46 x 106 N/m2
VHN3 = (18.188 x 20)/ (0.493 x 10- 3 ) 2 = 1496.65 x 106 N/m2
Average VHN = (VHN1+VHN2+VHN3) / 3
= {(1496.63+1455.02 +1455.02) x 106} / 3 N/m2
= 1493.04 x 106 N/m2
RESULTS:MATERIAL
VICKERS HARNESS
NUMBER (x106 N/M2)
1186.74
1493.04
1885.30
1431.76
Vickers Hardness No.
COPPER
BRASS
CAST IRON
MILD STEEL
2000
1800
1600
1400
1200
1000
800
600
400
200
0
1885.3
1493.04
1431.76
1186.74
COPPER
BRASS
CAST IRON
MILD STEEL
Materials
EXPERIMENT No. MT07

COMPRESSION TEST
AIM: To study the behaviour of the given materials under compressive loading and to determine
the following properties:
1. Maximum Compressive strength,
2. Proportional limit,
3. Elastic limit (Youngs modulus)
Universal testing machine,
Vernier Caliper,
Compression shackles.
Universal Testing Machine

Date:
Lab : MT Lab
Name:
Class: III Sem
USN:
Expt.No:
Title of the Experiment: COMPRESSION TEST

OBSERVATIONS:
Least count of Vernier Caliper =0.02mm
TABULATION
SL.
CHARACTERISTIC OF THE
NO.
SPECIMEN
1
.
BRASS
MILD STEEL
22.00
21.16
18.00
18.40
16.78
14.70
21.60
22.60
Initial Height of the specimen (hi) mm
2
.
MATERIAL
Initial Diameter of the specimen (di) mm
3
.
Final Height of the specimen (hf) mm
Final Diameter of the specimen (df) mm
TABULATION:
INITIAL SCALE READING = 100 mm
SL.
NO
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
MATERIAL : MILD STEEL

LOAD
SCALE
(KG)
READING (mm)
0
1000
2000
3000
4000
5000
6000
7000
8000
9000
14000
15000
16000
17000
18000
19000
20000
21000
22000
23000
24000
25000
14000
15000
100
101
101
101
101
101
101
101
101
101
102
103
104
104
105
105
106
106
106
106
107
108
102
103
SL. NO
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
MATERIAL : BRASS
LOAD (KG)
SCALE
READING
(mm)
0
10.0
1000
10.0
2000
10.0
3000
10.0
4000
10.0
5000
10.0
6000
10.0
7000
10.0
8000
100
9000
101
10000
101
11000
101
12000
101
13000
101
14000
101
15000
102
16000
103
17000
103
18000
103
19000
104
20000
104
21000
104
22000
104
23000
105
24000
105
25000
105
27.
28.
29.
26000
27000
28000
106
106
106
PROCEDURE :
1. Fix the lower and upper compression plates in between the bottom cross head and
intermediate crosshead.
2. Measure the initial diameter (di) and initial height (hi) of the given specimen using vernier
caliper.
3. Place the specimen at the centre of the bottom plate and bring the top of the specimen in
contact with the top plate by moving the intermediate cross head down wards.
4. Apply compressive load in steps of 1000 Kg.
5. The experiment is continued till the specimen attains a barrel shape on reaching the max load
for ductile materials or fractures at maximum load for brittle materials.
6. 6.Record load values and corresponding decrease in heights form the scale which is fixed to
the UTM.
7. Measure final height (hf ) and largest diameter of the specimen (df) using vernier caliper
8. Calculate stress and corresponding strain.
9. Plot the stress- strain diagram .
10. Calculate the youngs modulus from the graph
( Slope of the graph with in elastic limits)
MATERIAL : BRASS
INITIAL SCALE READING = 100 mm , A= 254.47mm2
SL NO
1
2
3
4
5
6
7
8
LOAD
(Kg)
0
1000
2000
3000
4000
5000
6000
7000
SCALE
READING
(mm)
100
100
100
100
100
100
100
100
STRESS
x106(N/m2)
STRAIN
0
38.55
77.10
115.65
154.20
192.75
231.30
269.85
0
0
0
0
0
0
0
0
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
8000
9000
10000
11000
12000
13000
14000
15000
16000
17000
18000
19000
20000
21000
22000
23000
24000
25000
26000
27000
28000
100
101
101
101
101
101
101
102
103
103
103
104
104
104
104
105
105
105
106
106
106
308.41
346.96
385.51
424.06
462.61
501.16
539.71
578.26
616.81
655.36
693.91
732.46
771.01
809.56
848.12
886.67
925.22
963.77
1002.32
1040.87
1079.42
0
0.045
0.045
0.045
0.045
0.045
0.045
0.091
0.136
0.136
0.136
0.182
0.182
0.182
0.182
0.227
0.227
0.227
0.273
0.273
0.273
MATERIAL: MILD STEEL

INITIAL SCALE READING :SL NO
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
LOAD
(Kg)
0
1000
2000
3000
4000
5000
6000
7000
8000
9000
10000
11000
12000
13000
14000
15000
16000
SCALE
READING
(mm)
100
100
100
100
100
100
100
100
100
101
101
101
101
101
101
102
103
STRESS
x106(N/m2)
STRAIN
0
38.55
77.10
115.65
154.20
192.75
231.30
269.85
308.41
346.96
385.51
424.06
462.61
501.16
539.71
578.26
616.81
0
0
0
0
0
0
0
0
0
0.045
0.045
0.045
0.045
0.045
0.045
0.091
0.136
18
19
20
21
22
23
24
25
26
27
28
29
17000
18000
19000
20000
21000
22000
23000
24000
25000
26000
27000
28000
103
103
104
104
104
104
105
105
105
106
106
106
655.36
693.91
732.46
771.01
809.56
848.12
886.67
925.22
963.77
1002.32
1040.87
1079.42
0.136
0.136
0.182
0.182
0.182
0.182
0.227
0.227
0.227
0.273
0.273
0.273
Material: Brass (Sl.No.2)
1.Stress = P/A = Load in Kgs x 9.81 / Initial Area
2.Initial Area (Ai) = di2/4 = x (18.00)2/4 = 254.47 mm2
= 245.47 x 10-6 m2
3.Stress = 1000 x 9.81 / (245.47 x 10-6) = 38.55 x 106 N/m2
4.Change in Height = Scale reading Initial Scale reading
= 100 100 = 0mm
5.Strain = Change in Height / Original Height
= 0/ 21.16 = 0.00
6.Final area (Af) = df2/4 = x (21.6)2/4 = 401.15 mm2
= 388.15 x 10-6 m2
7. % increase in area = (Af Ai) x 100 / Ai = 44.00
8. % decrease in height = (hf hi) x 100 / hi = 23.73
9. Compressive Strength = Max. Load / Initial Area
= 28000 x 9.81/ (245.47 x 10-6) = 10.79 x 108 N/m2
10. Modulus of elasticity (from graph) = 10.33 x 109 N/m2
B. Material: Mild Steel (For l.No.2)
1.Stress = P/A = Load in Kgs x 9.81 / Area
2.Initial Area (Ai) = di2/4 = x (18.00)2/4 = 254.47 mm2
= 245.47 x 10-6 m2
3.Stress = 1000 x 9.81 / (245.47 x 10-6) = 38.55 x 106 N/m2
4.Change in Height = Scale reading Initial Scale reading
= 101 100 = 1mm
5. Strain = Change in Height / Original Height

= 1/ 21.16 = 0.047
6. Final area (Af) = df2/4 = x (22.6)2/4 = 401.15 mm2
= 401.15 x 10-6 m2
7.
8.
9.
10.
% increase in area = (Af Ai) x 100 / Ai = 57.64

% decrease in height = (hf hi) x 100 / hi = 30.53
Maximum Compressive Strength = Max. Load / Initial Area
= 25000 x 9.81/ (245.47 x 10-6) = 9.64 x 108 N/m2
Modulus of elasticity (from graph) = 5.67 x 109 N/m2
SPECIMEN SKETCH
MATERIAL :DUCTILE
BEFORE TESTING
AFTER TESTING
MATERIAL :BRITTLE
BEFORE TESTING
AFTER TESTING
STRESS vs STRAIN GRAPH FOR BRASS MATERIAL
RESULT
SL.
NO.
PARAMETER
BRASS
MILD
1.
Decrease in height (%)
23.73
30.53
Increase in area (%)
44.00
57.64
Compressive strength ( N/m2)
10.7942x108
96.377x108
Modules of elasticity (N/m2)
1.033x109
5.67x109
S
T
E
E
L
EXPERIMENT No.S01&S02
PREPARATION OF SPECIMEN FOR METALLOGRAPHIC EXAMINATION &
MICROSTRUCTURE STUDY OF THE ENGINEERING MATERIALS
Objective: To study the microstructure of the given specimen (micro-section) and to
determine the grain size.
Apparatus: Hand press, flat file, emery papers of various grades, rotary polishing machine
and metallurgical microscope.
Theory: Micrography is the study of the structures of metals and their alloys under a
microscope at magnification from x75 to x1500. The observed structure is called the
microstructure. The metallographic studies include;
1.
2.
3.
4.
5.
Determination of size and shape of the crystallites, which constitute an alloy.

Reveal the structure characteristic of certain type of mechanical working operations.
Detect the micro-defects such as nonmetallic inclusions, micro cracks, etc.
Determine the chemical content of alloy.
It indicates the quality of heat treatment.
Preparation of specimens for microscopical examination: The various steps involved in

preparing a specimen for microscopic examination are given below.
1. Selection of specimen: When investigating the properties of a metal, it is essential that the
specimen must be homogeneous in composition and crystal structure. A specimen of 10mm
diameter or 10mm square is cut from the metal with a saw or water-cooled slitting wheel. The
thickness of the specimen should not be more than 12mm. When a specimen is so small that it is
difficult to hold, the specimen may be mounted in a suitable compound like thermoplastic resin, by
using a hand press. In cases where neither pressure nor heating is desirable, a cold setting
thermoplastic resin can be cast round the specimen, a specimen whose surface has been prepared
for micro analyses is called micro-section.
2. Grinding: It is primarily necessary to obtain a reasonably flat surface of the specimen. This can
be achieved either by using a fairly coarse file or by using motor-driven emery belt. Care must be
taken to avoid overheating of the specimen by rapid grinding methods; since this may lead to
alterations in the microstructure. When the original hacksaw marks have been ground out, the
specimen should be thoroughly washed.
3. Fine grinding: Fine grinding is carried out on waterproof emery papers of progressively finer
grades (220, 320, 400 and 600) that are attached to a plane glass plate. The specimen is drawn
back and forth along the entire length of No. 220 paper, so that scratches produced are roughly at
right angles to those produced by the preliminary grinding operation. Having removed the primary
grinding marks, the specimen is washed thoroughly. Grinding is then continued on No. 320 paper
and again turning the specimen through 900 until the previous scratch marks has been removed.
This process is repeated with No. 400 and No. 600 papers. Light pressure should be used at all
stages.
4. Polishing: The final polishing operation is to remove the fine scratches on the surface by using
a rotary polishing machine. The specimen is polished by rubbing it on a soft moist velvet cloth
mounted on a flat rotating disc, with the polishing paste. Suitable polishing pastes are fine
alumina, magnesia, Chromium oxide or diamond dust. Polishing is continued until a mirror
scratch free finish is obtained. Non-ferrous specimens are best finished by hand on a small piece
of selvyt cloth wetted with silvo polishing. This should be accomplished with a circular sweep of
the hand instead of back and forth motion used in grinding. During polishing a constant trip of
water is fed to the rotating pad. After polishing, the specimen must be washed thoroughly. The
grease films if any can be removed by immersing the specimen in boiling ethanol.
5. Etching: To make its structure apparent under the microscope, it is necessary to impart unlike
appearances to the constituents. This is generally accomplished by selectively corroding or etching
the polished surface by applying a chemical etching reagent. Grain boundaries will etch at
different rates than the grains, then leaving the grains standing out and they become visible with a
reflected light microscope.
EXPERIMENT No. D03

HEAT TREATMENT OF STEEL MATERIALS & STUDY OF THEIR HARDNESS
USING THEIR ROCK-WELL TESTING MACHINE
(ANNEALING AND NORMALIZING OF STEEL)
Objective: To heat treat the given steel specimen( anneal or normalize)and determine the
Rockwell hardness.
Apparatus: Austenitizing furnace (upto-1000C) and Rockwell hardness testing machine.
Theory: The microstructure of steel part can be modified by heat treatment techniques, that is, by
controlled heating and cooling of the alloys at various rates. These treatments induce phase
transformations that greatly influence mechanical properties of steel. The various heat-treatment
processes are annealing, normalizing, hardening and tempering.
Annealing of steel is the process of heating the steel specimen to its austenizing temperature,
holding it there long enough to dissolve the cementite and disperse the carbon uniformly and then
cool it very slowly to change the structure to the softest state. The low rate of cooling is achieved
by turning the furnace off and letting the closed furnace cool down to ambient temperature. The
annealing temperature of hypoeutectoid steel is
tanneal = Upper critical temperature + 30C to 50C
To avoid excessive softness in the annealing of steels, the cooling cycle may be done completely
in still air. This process is called normalizing. In normalizing, the part is heated to normalizing
temperature and is withdrawn from the furnace. It is then cooled in still air at the room
temperature. The more drastically cooled austenite decomposes into a more dispersed aggregate
made up of pearlite. After annealing and normalizing, a fine grain structure is obtained, provided
there is no super heating. The normalizing temperature is usually 30C to 50C more than that of
annealing temperature.
The purposes of annealing are:
1. To obtain softness.
2. To improve machinability.
3. To increase ductility and toughness.
4. To relieve internal stresses.
5. To refine the grain size. .
6. To prepare steel for subsequent cold working.
The purposes of normalizing the steel are:
1. To eliminate coarse-grained structure obtained in previous working (rolling, forging or
stamping).
2. To increase the strength of medium carbon steel.
3. To improve machinability of low carbon steel.
4. To reduce internal stresses.
Heat-treating furnace: A heat-treating furnace is a refractory lined chamber in which the metal
parts are heated to the required temperature. Usually the furnace consists of a box-like structure of
steel shell, door, refractory lining. heating source, temperature controls and temperature indicators.
Procedure for annealing:
1. Heat the given steel specimen in a box type furnace until the specimen reaches the annealing
temperature.
2. keep the specimen in the furnace at the annealing temperature for some time
3. Cool the specimen by switching off the furnace.
4. Remove the steel specimen from the furnace when the furnace is cooled down to atmospheric
temperature.
5. Determine the hardness of the annealed specimen using Rockwell hardness testing machine.
Procedure for normalizing:
1. Heat the given steel specimen in a box type furnace until the specimen reaches the
normalizing temperature.
2. keep the specimen in the furnace at the normalizing temperature for some time
3. Remove the steel specimen from the furnace when the furnace is cooled down to
atmospheric temperature.
4. Determine the hardness of the normalized specimen using Rockwell hardness testing
machine.
EXPERIMENT NO. MT05
WEAR TEST
AIM: To study the wear properties of the given specimen and to determine the wear rate.
APPARATUS/ TOOLS/ EQUIPMENT USED:
Wear testing machine

Tachometer
Scale
Digital weighing machine
Digital stopwatch.
THEORY: Wear is defined as the progressive loss or removal of material from a surface. Usually
parts damaged by wear can be repaired or replaced before disastrous failure takes place. Wear is
usually classified as adhesive, abrasive, corrosive, fatigue, fretting, and impact wear.
Adhesive wear: If a tangential force is applied between the two sliding blocks, shearing can take
place either at the original interface or along a path below or above it, causing adhesive wear. The
fracture path depends on whether or not the strength of the adhesive bond of the asperities is
greater than the cohesive strength of either of the two sliding bodies. Thus during sliding, fracture
at the asperity usually follows a path in the weaker or softer component. A wear fragment is then
generated. Although this fragment is attached to the harder component, it eventually becomes
detached during further rubbing at the interface and develops into a loose wear particle. This
process is known as adhesive wear or sliding wear. Adhesive wear can be reduced by:
1. Selecting materials that do not form strong adhesive bonds.
2. Using a harder material as one of the pair.
3. Using materials that oxidize more easily.
Abrasive wear: Abrasive wear is caused by a hard and rough surface sliding across a surface. This
type of wears removes particles by forming microchips, thereby producing grooves or scratches on
the softer surface. The abrasive wear resistance of metals is directly proportional to their hardness.
Abrasive wear can thus be reduced by increasing the hardness of materials or by reducing the
normal load.
Several methods can be used to observe and measure wear. In general a wear testing machine
consists of a means for applying load to a specimen of materials, which is rubbed at a given speed
over another piece of material or over an abrasive surface. The amount of wear after a given
amount of rubbing is measured either by loss of weight of the specimen or by dimensional
changes.
Wear Testing Machine
The material abrasion wear test machine is used to determine the wear coefficient of hard and soft
coating and monolithic materials by abrasive wear in a ball on plate contact configuration. The
machine may also be used as a crater generating tool on coated surfaces for coating thickness
determination. Test materials are paint films, plastic, coating, shoe material, slurry abrasion. This
system can do following wear test:
1. Ball Cratering Test
2. Grinding Process
3. Micro scale Abrasion
In general wear testing machine consists of a means for applying load to a specimen of material,
which is rubbed at a given speed over another piece of material or over an abrasive surface. The
amount of wear after a given amount of rubbing is measured either by loss of weight of specimen
or by dimensional changes

Date:
Lab : MT Lab
Name:
Class: III Sem
USN:
Expt.No:
Title of the Experiment: WEAR TEST

OBSERVATIONS:
Least count of Vernier Caliper = 0.02mm

Radius of wear track in meter (R) = 90mm
Speed of the wheel in RPM, (N) = 400
Length of the arm from specimen holder to load point (L1) =300mm
Length of the arm from specimen holder to Hanger point (L2) =150mm
Sliding time (T) = 10min
TABULATION:
Sl.
Specimen
No
Material
1
Aluminium
2
Brass
3
Aluminium
4
Brass
Load,
WH (Kg)
1
1
2
2
Weight (gms)
Initial (w1)
Final (w2)
0.951
0.949
2.411
2.325
0.949
0.946
2.325
1.158
Density,
(x103 kg/m3)
2.8
6.8
2.8
6.8
BHN
40
103
40
103
PROCEDURE:
1. Clean the surface of the disc and the specimen by alcohol and acetone.
2. Weigh the specimen in digital weighing machine, measure the length of the arm and the
track radius by using scale. Also a note down the length of specimen.
3. Fix the specimen on the horizontal arm using Allen key and place it on the disc.
4. Note down the speed of the disc and switch on the motor.
5. Load the specimen and adjust the displacement sensor to read zero.
6. Switch off the motor after the required interval of time 10 min.
7.
The final weight is recorded using digital weighing machine.
8. The wear coefficient and wear rate are calculated by the formulae
Wear coefficient K =
VH
and
FS
Wear rate in debris (mm3), V = Weight loss / Density of metal

= (Initial weight Final weight) / Density of metal
9. Repeat the above procedure to the other specimen for a given period at constant velocity.
Load may also be changed from 1 kg to 2 kg.
10. Repeat the procedure on the other specimens for given load by changing time, speed of the
track, track radius, etc.
Formulae used:Wear coefficient K =
VH
and
FS
Wear rate = V / S
Where
V = Volume of wear m3 = Weight loss /
Weight loss (Kg) = (W1 W2) / 100
W1 = Initial weight of the specimen (gms)
W2 = Final weight of the specimen (gms)
= Density of the metal (Kg/m3)
H = Hardness of material (B H N) N/m2
L = Normal load (Newton) = W x 9.81 x L1 / L2

W = applied load in Kgs,
L1 = length of the arm from specimen holder to load point in meter

L2 = length of the arm from specimen holder to hanger point in meter
S = Sliding distance (meter) = x D x N x T = 2 RNT
D = Diameter of wear track in meter
R = Radius of wear track in meter
N = Speed of the wheel in rpm and
T = Sliding time in minutes
Wear rate (mm3 / m) = V/S
V = Volume of wear in debris in mm3
S = Sliding distance in meter
Sl.
No
Specimen
Material
1
2
3
4
Aluminium
Brass
Aluminium
Brass
Load,
WH
(Kg)
1
1
2
2
Weight (gms)
Initial
Final
(w1)
(w2)
0.951
0.949
2.411
2.325
0.949
0.946
2.325
1.158
Density,
(x103
kg/m3)
2.8
6.8
2.8
6.8
BHN
40
103
40
103
Wear
coefficient
Kx10-12
2.49
113
1.90
110
Specimen Calculation
Material Aluminum
Least count of Vernier Caliper = 0.01 mm
Weight loss = W1 W2 = 0.951 0.949 = 2 x 10-3 gms = 2 x 10-6 Kg
Density of the metal, = 2.8 x 104 Kg/m3
Harness of material H = 40 B H N
Radius of wear track in meter R = 93 x 10-3 m
Speed of the wheel in rpm N = 400 rpm
Sliding time T = 10 min
Length of the arm from specimen holder to load point, L1 = 360 x 10-3 m
Length of the arm from specimen holder to hanger point in meter L2 = 150 x 10-3 m
For trial 1,
Load = 1 Kg
Initial Weight, W1 = 0.951 gms
Final Weight, W2 = 0.949 gms
Weight loss = W1 W2 = 0.951 0.949 = 2 x 10-3 gms = 2 x 10-6 Kg
Wear
rates,mm3/m
x10-13
3.0565
4.5845
Volume of material removed =
w1 w2 2 10 6
=
2.8 10 3
= 7.143 x 10-10 m3
H = 40
W H L 2
1 ( 9.81) 150 mm
= 4.905 N
Force F =
9.81 =
300 mm
L1
Sliding distance = 2RNT = 2 x 93 x 10-3 x 400 x 10 = 2337 m
7.143 10 10 40
Wear coefficient K 1 =
= 2.49 10 12
4.905 2337
Wear rate
= V / S = 7.143 x 10-10 / 2337

= 3.0565 x 10-13 mm3 / m
Advantages
i.
High reproducibility
ii.
Short test time
iii.
Simple flat test geometry
iv.
Simple operation
Disadvantages
i.
The tester does not have an arrangement for keeping the air humidity at a
constant level.
ii.
Large variations in humidity might affect the reproducibility.
iii.
Expensive
Department of Industrial Engineering and Management

R.V. College of Engineering, Bangalore 59
VIVA QUESTIONS
1.
How do you define the word 'Engineering Material?
2.
What are the objectives of testing of materials?
3.
Write brief classification of materials.
4.
List out the properties of materials.
5.
What is purpose of doing the following tests: Tensile Test, Compression Test, Shear Test,
Impact Test, Hardness Test
6.
In Tensile test, what is the nature of failure for brittle and ductile material?
7.
Define stress and strain. In what unit is each one measured?
8.
State Hook's law. Is this applicable to all materials?
9.
Define the following terms: elastic limit, proportional limit, yield point, yield strength,
resilience and toughness. Do all materials have yield point? Give examples
10.
What is the use of tensile test? What factor should be considered in selecting the gauge
length?
11.
Which property in a tension test is an indication of stiffness of a material?
12.
What is the difference between the proportional limit and the elastic limit?
13.
Distinguish between yield point and yield strength?
14. What are the uses of hardness test?
15.
What are the types of hardness measurement?
16.
What are the types of hardness test, with brief explanation?
17.
What are the advantages of Rockwell test over Brinell's Test?
18.
How do you define single shear and double shear?
19.
How do you place the specimens in impact test?
20.
What is metallography?
21.
What are the types of metallurgical microscopes?
22.
What are the steps involved for preparation of metallographic specimen?
23.
What is the purpose of conducting the wear test?
24.
What are the types of wear?
25.
What are the factors affecting wear?
26.
What is the importance of fatigue test?
27.
Describe the events that occur when a specimen undergoes a tension test.
28.
How is stress calculated? What additional measurement must be made to determine the
true stress?
29.
Explain why the difference between engineering strain and true strain becomes larger as
strain increases in tension?
30.
What is breaking stress? How does it differ from the maximum stress?
31.
If a brittle material and a ductile material have same tensile strength. Which one will
require the greater energy for fracture? Explain.
32.
Describe the difference between brittle and ductile fracture?
33.
What is universal testing machine? Describe briefly the mechanism for applying load, and
for measuring force in testing machine.
34.
What is the effect of rate of loading on tensile properties?
35.
What are the limits of ratio of the height to the diameter of the compression specimen?
36.
Explain compression fracture of the following materials: (a) cast iron, (b) mild steel and (c)
wood.
37.
How failure in bending occurs in the following materials? (a) Cast iron, (b) mild steel and
(c) wood.
38.
What physical property of the material is determined by means of an impact test?
39.
Discuss the significance and advantages of impact test compared with static tests.
40.
In what units are the results of an impact test usually given?
41.
For impact tests why are notch specimens used?
42.
What is difference between Charpy tests and Izod tests?
43.
What is meant by velocity sensitivity and notch sensitivity?
44.
What is the effect of temperature on impact toughness? What is a transition temperature?
45.
Explain the impact fracture as in the case of ductile material.
46.
Define hardness. Why is hardness test conducted instead of tension test?
47.
What physical properties of a material can be estimated from a hardness test?
48.
What is the unit for Brinell hardness number?
49.
Where are the Vickers and Rockwell hardness test employed?
50.
Why is a minor load applied before setting the Rockwell measuring dial?
51.
What is stress concentration? What is stress raiser?
52.
What is meant by the term fatigue of metals?
53.
Define the following terms in discussing fatigue tests: Stress cycle, maximum stress, range
of stress, minimum stress, normal stress, alternating stress, amplitude, mean stress, fatigue life,
fatigue limit, stress ratio, cycle ratio, fatigue strength and fatigue ratio.
54.
Explain why there is difference between a theoretical stress concentration factor and the
actual-strength reduction factor found in actual tests?
55.
What are the types of fatigue loading? Give examples of machine parts and structures
subjected to fatigue loading.
56.
If a material does not have an endurance limit, how would you estimate its fatigue life?
57.
What type of fracture would you expect in the case of steel member fractured by repeatedly
applied loads? Explain the mechanism of such fracture.
58.
What is creep? Name two structural or machine members in which creep strength is an
important property.
59.
State the resemblance and the difference between creep and slip?
60.
Does wood creep? State evidence for your answer.
61.
Define wear of the material. Name different types of wear.
62.
Define micrography.
63.
What are the general objectives of the macro examination of a metallic component as
compared with the micro examination of a metal?
64.
Describe the various steps involved in preparation of specimen for micrographic
examination.
65.
What is the difference between eutectic and eutectoid?
66.
Explain the Curie point in iron, iron-carbide equilibrium diagram.
67.
What is annealing? What are the purposes for annealing steel?
68.
How does normalizing differ from annealing as applied to steels?
69.
What are the advantages of the normalizing process in respect of final properties?
70.
Describe the hardening process. Where does the defect occur after hardening the steel?
71.
Explain what happens in steel when it is hardened by quenching.Name several quenching
media.
72.
What is age hardening?
73.
Explain the difference between hardness and harden ability?
74.
What is tempering? What purpose does it serve?
75.
Why steel specimen should be tempered after hardening?
76.
Both annealing and tempering are the processes used to soften steel. Outline the conditions
when these treatments would be used.
77.
Identify the non-destructive technique that is capable of detecting internal flaws and those
that detect external flaws only.
78.
How is the depth of a flaw measured in ultrasonic testing?
79.
On what principle does ultrasonic inspection equipment operates?
80.
Describe the magnetic particle method.

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Department of Industrial Engineering and Management, R.V. College of Engineering, Bangalore 59.

Dept. of Industrial Engineering & Management

Material Testing lab Manual

Department of Industrial Engineering and Management

SUBJECT CODE: MEL37 A

Material Testing lab Manual

= Class work total + Test Marks

Material Testing lab Manual

Material Testing lab Manual

6. Ultimate Tensile Strength

These tests are classified into three categories:

Material Testing lab Manual

EXPERIMENT No. MT01

TENSION TEST ON DUCTILE MATERIAL

Material Testing lab Manual

Material Testing lab Manual

Title of the Experiment: TENSION TEST

SKETCH OF THE SPECIMEN:

Material Testing lab Manual

Title of the Experiment: TENSILE TEST

Material Testing lab Manual

Signature of the staff in charge

Title of the Experiment: TENSILE TEST

Material Testing lab Manual

Signature of the staff in charge

Material Testing lab Manual

5. Strain = Change in length / Original length = 0.035/120= 0.000333

Material Testing lab Manual

EXPERIMENT No. MT02

Torsion testing machine,

Material Testing lab Manual

R.V. COLLEGE OF ENGINEERING, BANGALORE-560059

Title of the Experiment: TORSION TEST

Signature of the staff in charge

Material Testing lab Manual

PROCEDURE:1. Measure the dimensions of the specimen using Vernier caliper

Shear Stress (x10 8 N/m )

Material Testing lab Manual

SPECIMEN CALCULATION (for sl.no.2)

Material Testing lab Manual

= 5.0961 x108 N/m2

EXPERIMENT No. MT03

IMPACT TEST IZOD AND CHARPY

Impact testing machine,

Material Testing lab Manual

height h', lower than the initial position of the pendulum.

h & h= Specified height

R.V. COLLEGE OF ENGINEERING, BANGALORE-560059

Title of the Experiment: IMPACT TEST--- IZOD

Material Testing lab Manual

Signature of the staff in charge

Material Testing lab Manual

Material Testing lab Manual

TABULATION AND CALCULATION:Material

SPECIMEN CALCULATION (For Mild Steel):-

Actual energy absorbed by the specimen during fracture

Material Testing lab Manual

Material Testing lab Manual