vrrrbeessisbesshessrr thy EXPERIMENT NO. - 01 Study of Universal Testing Machine (U.T.M.) To Study the various component parts of the Universal Testing Machine (U.T.M.) & test procedures of various practical’s to be performed. Universal Testing Machine with all attachment i.e. shears test attachment, bending attachment, tension grips, compression test attachment etc. [eeeuee-ope nue) 1] [Specimen i [_—Lesd measring | Ie gauge Control ) ' | HI i} a Piston Motor, Pump. Ve i x L ’ | __-Cylinder Fig.1 Universal Testing Machine ° Fig.2 Mild Steel Specimens TOTETER ET TTT TOOT TOPTT TITHEORY: The Universal Testing Machine consists of two units. (1) Loading unit (2) Control panel Loading Unit: It consists of main hydraulic cylinder with a piston inside which moves up and down. The chain driven by electric motor which is fitted on left hand side. The screw column maintained in the base can be rotated using above arrangement of chain. Each column passes through the main nut which is fitted in the lower cross head. The lower table connected to main piston through a ball & the ball seat is joined.to, ensure axial loading. There is a connection between lower table and upper hitad assembly that moves up and down with main piston. The measurement of this assembly is carried out by number of bearings which slides over the columns. The test specimen each fixed in the job is known as ‘Jack Job’. To fix up the specimen tightly, the movement of jack job is achieved helically by handié, Control Panel: It consists of oil tank having a hydraulic oil level sight glass for checking the oil level. The pump is displacement type piston pump having free plungers those ensure for continuation of high pressure, The pump is fixed to the tank from bottom, The suction & delivery valve are fitted to the pump near tank. Pump driven by the electric moior is mounted on four studs which are fitted on the right side of the tank. There is an arrangement for loosing or tightening of the valve. The four valves on control panel control the oil stroke in the hydraulic Sysiem. During loading the retura valve is close, and oil delivered by the pump through the flow’ control valves to the cylinder and the piston goes: up. As Pressure starts developing the specimen is subjected to stress and breaks away. The switches'have uoper and lower push at the control panel for the downward & upward movement of the movabie head. The-on and off switches are provided on the control panel and the pilot lamp shows the transmission of main supply.METHOD OF TESTING: Tension Test - Select the proper job and complete upper and lower check adjustment. Then operate the upper cross head grip operation handle & grip the upper end of test specimen fully in to the groove. Keep the lower left valve in fully close position. Open the right valve & close it after lower table is slightly lifted. Adjust the lower points to zero with the help of adjusting knob. This is necessary to remove the dead weight of the lower table. Then lock the jobs in this position by operating job working handle. Then open the left control valve. The printer on dial gauge at which the specimen breaks slightly return back & corresponding load is known as breaking load & maximum load is known as the ultimate load. Compression Test - Fix upper and lower pressure plates to the upper-stationary head & lower table respectively. Place the specimen on the lower plate in order to grip. Then adjust zero by lifting the lower table. Then perform the test in the same manner as described in tension test. Flexural or Bending Test - Keep the bending table on the lower table in such a way that the central position of the bending table is fixed in the central location value of the lower table. The bending supports are adjusted to required distance. Then place the specimen on bending table & apply the load by bending attachment at the upper stationary head. Then perform the test in the same manner as described in tension test. Brinell Hardness Test - Place the specimen on the lower table & lift it up slightly. Adjust the zero fixed value at the bottom side of the lower cross head. Increase the load slowly till ultimate load value is obtained. ‘Then release the load slowly with left control valve. Get the impression of a suitable value of five to ten millimeter on the specimen & measure the diameter of the impression correctly by microscope & calculate Brinell hardness, Shear Test - Place the shear test attachment on the lower table, this attachment consists of cutter. After inserting the specimen in holes of shear test attachment, lift the lower table so that the zero is adjusted, then apply the load such that the specimen breaks in two or three pieces. If the specimen breaks in two pieces then it will be in angle shear, & if it breaks in three pieces then it will be in double sheer.STUDY OF EXTENSOMETER: This instrument is an attachment to Universal / Tensile Testing Machines. This measures the elongation of a test piece on load for the set gauge length. The least count of measurement being 0.01 mm and maximum elongation measurement up to 3 mm is possible. This elongation measurement helps in finding out the maximum stress at the required percentage elongation. Fig.3 Extensometer Working - The required gauge length (between 30 to 120 mm) is set by adjusting the upper knife edges. A scale is provided for this purpose. Hold the specimen in the upper and lower jaws of Tensile / Universal Testing Machine. Position the extensometer on the specimen. Position upper clamp to press upper knife edges on the specimen. The extensometer will be now fixed to the specimen by spring pressure. Set zero ‘on both the dial gauges by zero adjust screws. Start loading the specimen and take the reading of load on the machine at required elongation or the elongation at required load. Force setter accuracies mean of both the dial gauge readings should be taken as elongation. It is very important to note & follow the practice of removing the extensometer from the specimen before the specimen breaks otherwise the instrument will be totally damaged. As a safety, while testing the instrument may be kept hanging from a fixed support by a slightly loose thread. ‘Technical Specification - Measuring Range :0-3 mm. Least Count 20.01 mm. Gauge Length adjustable from : 30-120 mm Specimen Size : 1 to 20mm Round or Flats up to 20 x 20 mm.Stress stress /Pa A) Stress-strain graph of Mild Steel é A Proportional Limit B- Elastic Limit abs F C - Upper yield point D - Lower yield point S E — Ultimate stress point F — Breaking stress point Strain B) Stress-strain graphs of different materi AA brittle material. This meterial is also strong because there is litle strain fora high stress. The fracture of a brite materal is sudden with litte or no plastic deformation. Glass is brittle A strong material which is not ductile. Stee! wites streton vety lille, and break suddenly. A ductile material after the elastic region theres s strange secton where necking Occus - permanent deformation aecurs in this plastic region - Aplastic material very small elestic region. € (strain)EXPERIMENT NO. - 02 AIM: OBJECTIVE: APPARATUS: DIAGRAM: Moter. To determine tensile strength of mild steel. To conduct a tensile test on a mild steel specimen and determine the following: (i) Limit of proportionality (iii) Yield strength (v) Young’s modulus of elasticity (vii) Percentage reduction in area. (i) Universal Testing Machine (iii) Extensometer ‘Control ey uy (ii) Elastic limit (iv) Ultimate strength (vi) Percentage elongation (ii) Mild steel specimens (iv) Vernier Caliper Specimen Load meaeuring enuge: Fig.l Universal Testing Machine Agee Pump. pda @ Fig.2 Mild Steel Specimens compression(or strain) deformation ‘compressive load (or stress) I~ AA compression test can be performed on UTM by keeping the test-piece on base block (see in fig.) and moving down the central grip to apply load. A UTM for compression testing has two compression plates/heads. The upper head is moveable while the lower head is stationary. Uniform distribution of load over the test-piece ends. A load gauge is fitted for recording the applied load. SPECIMEN: In cylindrical specimen, it is essential to keep h/d < 2 to avoid lateral instability due to bucking action. Specimen size=h< 2d. PROCEDURE: . Dimension of test piece is measured at three different places along its height/length to determine the average cross-section area. Ends of the specimen should be plane. For that the ends are tested on a bearing b plate. 3. The specimen is placed centrally between the two compression plates, such that 6 the centre of moving head is vertically above the centre of specimen. 4. Load is applied on the specimen by moving the movable head. 5. The load and corresponding contraction are measured at different intervals. The load interval may be as 50 KN. 6. Load is applied until the specimen fails. RESULT: ‘The compressive strength of given specimen = N/mm? PRECAUTION: 1. The specimen should be prepared in proper dimensions. 2. The specimen should be properly mounted to get between the compression plates, © 3. Take reading carefully. 4, After specimen fails, stop to machine.EXPERIMENT NO. - 04 AIM: To determine Shear strength of mild steel. OBJECTIVE: — To conduct shear test on specimens under double shear on a mild steel rod, APPARATUS: _ i) Universal testing machine. ii) Shear test attachment. iii) Specimen. DIAGRAM: Moving Pate Stationary Plate StationeryPate Specimen Double Shear Test THEORY: Place the shear test attachment on the lower table, this attachment consis‘s of cutter. ‘The specimen is inserted in shear test attachment & before the test the lower table is slightly lifted, so that the zero is adjusted. During test the load is applied gradually such that the specimen breaks in two or three pieces. If the specimen breaks in two pieces then it will be called as single shear & if it breaks in three pieces then it will be called as double shear.PROCEDURE: 1. Insert the specimen in position and grip one end of the attachment in the upper portion and one end in the lower portion. 2. Switch on the main switch of universal testing machine. 3. The drag indicator in contact with the main indicator. 4, Select the suitable range of loads and space the corresponding weight in the pendulum and balance it if necessary with the help of small balancing weights. 5, Operate (push) buttons for driving the motor to drive the pump. 6. Gradually move the head control level in left-hand direction till the specimen shears. 7. Down the load at which the specimen shears. 8. Stop the machine and remove the specimen. RESULT: ‘The Shear strength cf mild steel specimen is found to be PRECAUTION: 1. The measuring range should not be changed at any stage during the test. 2. The inner diameter of the hole in the shear stress attachment should be slightly greater than that of the specimen. 3. Measure the diameter of the specimen accurately.EXPERIMENT NO. - 05 AIM: Determination of Rockwell Hardness Number of given material by Rockwell hardness testing machine. OBJECTIVE: — To conduct hardness test on mild steel specimen. APPARATUS: — Rockwell Hardness tester and mild steel specimen. DIAGRAM: Specimen table (Anvil) indenter: Blevating suche serew Hand wheel —_ “=| | fe & Loading lever Figal Rockwell Hardness Tester Load 100 kg Fig.2 Intender on mild steel specimenTHEORY: Hardness is defined as resistance to abrasion, resistance to scratching and ability of metal to cut another metal. The hardness values of engineering materials are mostly obtained by the penetration method. In this method material is subjected to know magnitude of load mechanically applied through a very hard and specially chosen intending tool called as intender. This intender under the influence of impressed load penetrates into the surface of material thereby leaving a permanent impression. The dimensional measurement of such an impression is important factor for knowing the hardness value of different materials. In this test, diamond cone of 120° with spherical lip is employed. Description of Set-up:- The testing machine has a dial indicator which has two scales of hardness B and C depending upon the material to be tested. The specimen is placed on anvil and it is raised by hand lever till it comes in contact with intender. The hardness tester body is made of cast iron and the main screw is protected by rubber grip. The weights are applied on the dashpot which transmits the pressure on plunger and thereby on work piece for determination of hardness value. Seale oral] Dist] “Typical appliations symbol ant| indenter | toed | Nomeraa| "ofan Petite cy ‘& [oamora [eo | since [Camere aroiay ne lene ie alow dept vane wet “P [isitme [102 | Ret [oppor alors ah lace | | Sees smini aay, ea mallesie em B_|Dawoni | 100 | Back | Tala sen, medio, on dept case ardaned ais cet a F [item | 60 | Red | Annes coppr are, dinate ‘Sine obeat merle © [iste [iso] Rel at HW [savsmm| 60) Ret Si ee ea [xargs | 150 | Red [Sot bene me sa Fig3 Rockwell Hardness ScalePROCEDURE: (1) Put the weight on plunger of dash pot according to Rockwell Scale as shown in the table of hardness tester. (2) Tum the hand wheei in clockwise direction so that specimen will push the intender and show a reading on dial gauge. (3) Turn the lever at position B to A slowly so that total load is brought into action without jerks. (4) When the long pointer of dial gauge réaches to a steady position, take back lever slowly. (5) Read off the figure against long pointer i.e. direct reading for hardness of specimen. (6) Turn back hand wheel and remove specimen. (7) Carry on the same procedure for the next reading. (8) Take 3 to 4 readings and calculate average. OBSERVATION TABLE: Reading No. HRB a Average RESULT: The Rockwell hardness number (HRB) is found to be : PRECAUTION: (1) The intender and anvil should be clean and well placed. (2) The surface of the specimen should be flat, clean, dry, smooth and should be perpendicular to intender. (3) The test should be carried out preferably at a temperature 27 + 2° C. (4) The thickness of the test piece must be at least 10 times the depth of indentation. (5) The spacing between indentations should be 3 to 5 times the diameter of intender.EXPERIMENT NO. - 06 To determine Young’s modulus of beam material and it’s bending strength by deflection. OBJECTIVE: — To determine the bending strength and Young’s modulus of simply supported beam by application of point load at center. APPARATUS: _ 1.Universal testing machine with bending fixture. 2. A steel beam. DIAGRAM: : z z i Batnut Ballscrew Test Specimen , Opposing Tapered Roller Bearings Rotary. Syaclomnes Encoder One vee Deflection Test on UTM THEORY: If a beam is simply supported at the ends and carries a concentrated load at its centre, the beam bends concave upwards. The distance between the original position of the beams before bending and its position after bending at different points can be seen, which will be maximum at the centre in this case. This difference is known as ‘deflection’ In this particular type of loading (with point load at the centre) the maximum amount of deflection (6) is given by the relation: we 3 we py eR = 48El 851Where, W = Load acting at the center, N 1 =Lenath of the beam between the supports, mm E =Young’s modulus of material of the beam, N/mm? I= Moment of inertia of the cross- section about the neutral axis, mm* PROCEDURE: . Adjust cast- iron block along the bed so that they are symmetrical with respect to the length of the bed. n . Place the beam on the knife edges on the block so as to project equally beyond each knife edge. See that the load is applied at the centre of the beam. 3. Go on adding a load of and note the reading. B . Find the deflection (6) in each case. e a - Draw a graph between load (W) and deflection (6). On the graph choose any two convenient points and between these points find the corresponding values of W and 5. 3 we 6. Putting these Values in the relation E = 7 determine Young's modulus. RESULT: The young’s modulus for steel beam is found to be ‘The bending strength of beam is found to be ... PRECAUTION: 1. Make sure that beam and load are placed a proper position, 2. The point load on the beam should be gradually applied.EXPERIMENT NO. - 07 AIM: To determine shear modulus of a circular steel shaft. OBJECTIVE: — To conduct torsion test on mild steel shaft to find out its shear modulus (modulus of rigidity). APPARATUS: __ 1. A torsion testing machine. 2, Twist meter for measuring angles of twist 3. A steel rule and Vernier Caliper or micrometer. DIAGRAM: LE 4 Enlarged view of Enlarged views of end of -— praduated scale the specimen Hates. Pa Specimen Jaws To Testing Machine THEORY: A torsion test is quite instrumental in determining the value of modulus of rigidity of a metallic specimen. The value of modulus of rigidity can be found out thought observations made during the experiment by using the torsion equation: rt coWhere, T= Torque applied J=Polar moment of inertia T = Shear stress adius of shaft C=Modulus of rigidity = Angle of twist (in radians) 1= Length of the shaft PROCEDURE: L. Select the driving dogs to suit the size of the specimen and clamp it in the machine by adjusting the length of the specimen by means ofa sliding spindle. 2. Measure the diameter at about three places and take the average value. 3. Choose the appropriate range by capacity change lever 4. Set the maximum load pointer to zero. 5. Set the protector to zero for convenience and clamp it by means of knurled screw. 6. Carry out straining by rotating the hand wheel in either direction. 7. Load the machine in suitable increments. 8. Then load out to failure as to cause equal increments of strain reading. 9. Plot a torque- twist (T- 0) graph. 10.Read off co-ordinates of a convenient point from the straight line portion of the torque twist (T- 0) graph and calculate the value of C by using relation OBSERVATION: Gauge length of the specimen, 1= Diameter of the specime = Polar moment of inertia,OBSERVATION TABLE: Readings 1 2 3 4 5 6 7 8 9 10 Torque | mm) Angle of twist (9) RESULT: Modulus of rigidity of mild steel rod is ... PRECAUTION: 1) Measure the dimensions of the specimen carefully. 2) Measure the Angle of twist accurately for the corresponding value of Torque.EXPERIMENT NO. - 08 AIM: To determine impact strength of a wood Sample. OBJECTIVE: — To perform Izod impact test and determine the maximum energy absorbed by wood sample, before fracture. APPARATUS: __ Impact testing machine. 2. A wood specimen 75 mm X 10mm X 10mm. DIAGRAM: Striking hammer Izod Impact Test THEORY: An impact test signifies toughness of material that is ability of material to absorb energy during plastic deformation. Static tension tests of un-notched specimens do not always reveal the susceptibility of a metal to brittle fracture. This important factor is determined by impact test. Toughness takes into account both the strength and ductility of the material. Several engineering materials have to withstand impact or suddenly applied loads while in service. Impact strengths are generally lower as compared to strengths achieved under slowly applied loads. Of all types of impact tests, the notch bar tests are most extensively used. Therefore, the impact test measures the energy necessary to fracture a standard notch bar by applying an impulse load. The test measures the notch toughness of material under shock loading. Values obtained from these tests are not of much utility to design problems directly and are highly arbitrary.Still it is important to note that it provides a good way of comparing toughness of various materials or toughness of the same material under different condition. This test can also be used to assess the ductile brittle transition temperature of the material occurring due to lowering of temperature. PROCEDURE: IZOD Test 1. With the striking hammer (pendulum) in safe test position, firmly hold the steel specimen in impact testing machine’s vice in such a way that the notch face the hammer and is half inside and half above the top surface of the vice. 2. Bring the striking hammer to its top most striking position unless it is already there, and lock it at that position. 3. Bring indicator of the machine to zero, or follow the instructions of the operating manual supplied with the machine. 4, Release the hammer. It will fall due to gravity and break the specimen through its momentum, the total energy is not absorbed by the specimen. Then it continues to swing. At its topmost height after breaking the specimen, the indicator stops moving, while the pendulum falls back. Note the indicator at that topmost final position. 5. Again bring back the hammer to its idle position and back. OBSERVATION: Impact value of wood sample is .. RESULT: The energy absorbed by the wood sample is found out to be .......e.s. Joules. PRECAUTION: 1. Measure the dimensions of the specimen carefillly 2. Hold the specimen (Izod test) firmly. 3. Note down readings carefully.