SATHYABAMA UNIVERSITY

CHENNAI -600 119

DEPARTMENT OF MECHANICAL
ENGINEERING



MATERIAL TESTING LAB MANUAL


CONTENTS


LIST OF EXPERIMENTS

1. COMPRESSION TEST ON BRICKS.CONCREATE BLOCS.
2. DEFLECTION TEST
3. COMPRESSION TEST ON OPEN COILED HELICAL SPRING
4. TENSION TEST ON CLOSED COILED HELICAL SPRING
5. DOUBLE SHEAR TEST U.T.M
6. IZOD/CHARPY IMPACT TEST
7. TENSION TEST ON MILD STEEL BAR
8. ROCKWELL HARDNESS TEST
9. BRINELL HARDNESS TEST
10. VICKERS HARDNESS TEST
12 LOAD MEASUREMENTS USING LOAD INDICATOR & LOAD COILS











1. COMPRESSION TEST ON WOOD/ BRICK

AIM :

To determine the compressive strength of a given wooden specimen .

APPARATUS REQUIRED:
Compression testing machine
1. Scale .

PROCEDURE :

1. Measure the dimensions of the specimen .
2. Keep the wooden specimen at the centre of the lower compression plate .Now lower the
adjustable cross head by rotating the hand wheel so that the top compression plate just
touches the specimen .
3. Now apply the load manually. Now the specimen is compressed between the compression
plates .The load applied to the specimen is indicated by the measuring value indicator .
4. Load the specimen till it fails .Note the ultimate load .
5. Remove the specimen from the machine .

OBSERVATION :
C . S dimensions of the specimen = mm





TABULATION :



CALCULATION:
Ultimate compressive load (N)
Compressive strength of the given specimen( N/mm) = ---------------------------------
C. S area of the specimen (mm)
RESULT :
The compressive strength of the given specimen = (N/mm)


Sl .No


Load in N

Cross sectional area of
the specimen
( mm
2
)

Compressive strength
N / mm
2


















2.DEFLECTION TEST
AIM :

To determine the Youngs modulus of the given material and verify Maxwells law of
reciprocal deflection .

APPARATUS :

1. Knife edge supports
2. Deflectometer
3. Set of weights with hanger.
4. Scale
5. Vernier caliper .

PRINCIPLE :

According to Maxwells law of reciprocal deflection in a simply supported beam

AB
=
BA
where
AB
- Deflection of the beam measured at A due to the load at B

BA
- Delection of the beam measured at B due to the load at A
PROCEDURE :

1. Measure the dimensions of the beam.
2. Place the given beam on knife edge supports with equal overhangs on either side of the
beam .
3. Place the deflectometer at a distance x from the support.
4. Place the weight hanger at a distance of a from the support. Note the initial reading of
the deflectometer.
5. Now increase the load gradually and take the corresponding deflectometer readings.
6. Now decrease the load in the same intervals and note the deflectometer readings.
7. Draw a graph - Load vs Deflection .

OBSERVATION :
x < a & x < b
C . S . dimensions of the beam =

Span ( l ) = mm
Distance ( x ) = mm
Distance ( a ) = mm
Distance ( b ) = mm
TABULATION :

S.No

Load

Deflectometer reading Youngs
modulus
in
N/mm
2

x < a x < b
gm N Loading
mm
Unloading
mm
Mean
mm
Loading
mm
Unloading
mm
Mean
mm
1.

2.
3.
4.
5.
6.


CALCULATION:

x < a
w b x
= ------------ ( l
2
- b
2
- x
2
)
6 E I l

x < b
w a x
= ------------ ( l
2
- a
2
- x
2
)
6 E I l

RESULT :

Youngs modulus of the given material (E) = (N/mm)











3. COMPRESSION TEST ON OPEN COILED HELICAL SPRING

AIM :

To conduct a compression test on the given helical spring and hence determine the
following, a) Shear modulus b) Stiffness of the spring c) Proof load d) Strain energy stored
at proof load

APPARATUS :

1. Spring testing machine
2. Vernier caliper
3. Scale

MACHINE DESCRIPTION :

The machine mainly consists of loading mechanism, load measuring system, indicating
mechanism, recorder and electrical controls.
Loading mechanism :
The base is connected to torque plate by two columns forming the main structure of the
machine .The measuring system is assembled on top plate and is covered by top cover. The side
panel fixed to the right column consists of indicating and recording mechanisms
Load measuring sytems (Pendulum dynamometer):
The load measuring system is supported on the top plate and is covered by the top cover.
The upper grip head is fixed to the central member .A spring steel strip with one end fixed to the
pendulum shaft runs around the shaft and its end is fixed to the central member.
Indicating mechanism:
The rack pusher fixed to the pendulum lower pushes the rack which slides over the rack
guide pulleys .The lower movement of the rack rotates the pinion .The pinion is fixed on a pointer
shaft running in ball bearing. A dummy pointer which moves forward with the main pointer is
provided for maximum load reading .

PROCEDURE :

1. Measure the mean coil diameter and the diameter of wire of the spring .Also note the
number of free coils in the spring.
2. Place the spring in position in between the platforms for compression spring.
3. Adjust the indicator of the load dial, to read 0.
4. Apply compressive load by increasing at suitable intervals and note the corresponding
deflections.
5. Draw graph - load vs deflection .



OBSERVATION :

Mean coil diameter ( D ) = (N/mm)

Wire diameter (d ) = (N/mm)

No. of turns ( n ) =

Free height of the spring (H) = (N/mm)



TABULATION :


S.No
Load
(N )

Deflection (mm )

Stiffness
(N/mm)
Proo
f
Load
( N)
Shear
stress
(N/mm)

Rigidity
modulus
(N/mm)
Strain
energy
(N-mm)
Loading Unloading Mean
1.

2.

3.

4.

5.

6.

7.

8.

9.

10.



CALCULATION:
64 R
3
n w
Rigidity modulus ( G ) = ------------- x --------------- (N/mm)
d
4


w
Stiffness of the spring ( K ) = ----------- (N/mm)

Proof load (w
p
) = K (H - n d ) (N)

16 w
p
R
Shear stress ( p ) = -------------- = (N/mm)
d
3

(p )
2
d
2

Strain energy stored ( Uwp ) = -------------- x --------- x Dn (N/mm)
4 G 4


RESULT :

Rigidity modulus = (N/mm)

Stiffness of the spring = (N/mm)

Proof load = (N)

Strain energy stored at proof load = (N/mm)




4. TENSION TEST ON CLOSED COILED HELICAL SPRING

AIM :

To conduct a tension test on the given helical spring and hence determine the
following a) Shear modulus b) Stiffness of the spring.

APPARATUS :

1. Spring testing machine
2. Vernier caliper
3. Scale

MACHINE DESCRIPTION :
The machine mainly consists of loading mechanism, load measuring system, indicating
mechanism, recorder and electrical controls.
Loading mechanism:
The base is connected to torque plate by two columns forming the main structure of the
machine. The measuring system is assembled on top plate and is covered by top cover. The side
panel fixed to the right column consists of indicating and recording mechanisms
Load measuring systems (Pendulum dynamometer ):
The load measuring system is supported on the top plate and is covered by the top
cover.The upper grip head is fixed to the central member .A spring steel strip with one end fixed
to the pendulum shaft runs around the shaft and its end is fixed to the central member.

Indicating mechanism :

The rack pusher fixed to the pendulum lower pushes the rack which slides over the rack
guide pulleys .The lower movement of the rack rotates the pinion .The pinion is fixed on a pointer
shaft running in ball bearing. A dummy pointer which moves forward with the main pointer is
provided for maximum load reading .
PROCEDURE :

1. Measure the mean coil diameter and the diameter of wire of the spring .Also note the
number of free coils in the spring .
2. Place the spring in position by attaching it to hooks for tension spring .
3. Adjust the indicator of the load dial ,to read 0 .
4. Apply tensile load by increasing at suitable intervals and note the corresponding
deflections .
5. Draw graph - load vs deflection.

OBSERVATION :

Mean coil diameter (D) = mm

Wire diameter (d ) = mm

No. of free coils ( n ) =






TABULATION :


S.No
Load
(N )

Deflection (mm )

Stiffness
N/mm
Shear
stress
N/mm
2
Rigidity
modulus
N/mm
2

Strain
energy
N-mm
Loading Unloading Mean
1.

2.

3.

4.

5.

6.

7.

8.

9.

10.




CALCULATION:

64 R
3
n w
Rigidity modulus ( G ) = -------------- x ---------
d
4


w
Stiffness of the spring ( K ) = ---------------

16 w

R
Shear stress ( ) = ------------
d
3

( )
2
d
2

Strain energy stored ( Uwp ) = -------------- x --------- x Dn
4 G 4


RESULT :

Rigidity modulus (N/mm) =

Stiffness of the spring (N/mm) =

Proof load (N) =

Strain energy stored at proof load =




5 DOUBLE SHEAR TEST U.T.M

AIM
To determine the shear strength (ultimate shear stress) of the mild steel specimen supplied using
double shear method.
EQUIPMENT
UTM, Shear attachment to the UTM, shear dies and Venire Calipers.
THEORY AND PRINCIPLE
Shear strength of the material is the ultimate shear stress ( ) attained by the specimen,
which under double shear given by,

Where,
F = Maximum load at which the specimen breaks, and
A = cross-sectional area of the specimen.
The load range to which the machine is to be set for the test is selected bases on the expected
maximum load F to be applied on the specimen. This is calculated from the yield stress fy and the
factor of safety , as follows:
Permissible shear stress t for mild steel is,

And therefore,
________________________(2)

PROCEDURE
Measure the diameter of the specimen. Calculate the maximum load expected to be applied on
the specimen using equation (2) and select the load range to be used. Set the UTM for the
selected load range. Set the correct set or dies to assemble the shear attachment with the right
set of dies in it. Insert the specimen in to the dies so that it projects equally on either side. Place
the entire bear assembly with the specimen in it centrally over the baring plate on the lower
table. Bring the lower cross- head close to the top surface of the assembly. Float the lower table
and set the load pointer to zero. Apply the load gradually until the specimen breaks. Note the
ultimate load applied on the specimen.
OBSERVATION
The observation taken are tabulated in Table
Calculations
(i) Range
Using equation (2) and taking fy = 250 N/mm2 and =3 and, expected maximum load to be applied
on the specimen is,
F = 30.45250/2A
(ii) Shear strength
Using equation (1) the ultimate shear stress is= F/2=___________
RESULT
Ultimate shear stress of the material is fount to be N/mn^
2





6. IZOD IMPACT TEST

AIM :
To determine the impact strength of the given specimen.
APPARATUS REQUIRED:
1. Izod impact testing machine
2. Scale
.
MACHINE DESCRIPTION :

The pendulum impact testing machine consists of the single piece frame, the pendulum,
the specimen support and the measuring equipment. The pendulum is fastened to the pendulum
shaft. The range within which the pendulum is swinging is partially protected by the guard. There
is a dial attached concentrically with the pendulum shaft. The scale is designed such that the
impact energy absorbed in breaking the specimen can be read directly.
(i) Angle of drop of pendulum = 90
0

(ii) Striking velocity of pendulum = m / sec
PROCEDURE :

1. Firmly secure the proper striker to the bottom of the hammer with the help of damping
piece.
2. Firmly secure the latching tube for Izod test to the barring housing at the side of the
columns. The steel wire coming from the latch is carried through the latching tube and is
fastened to the interior of the release lever.
3. For determining the frictional loss in the machine, adjust the reading pointer along with
pointer carrier to 300 J reading on the dial when the pendulum is swinging free.
4. Note the reading on the scale against the pointer, which gives initial error if any.
5. Now lift the pendulum again to its starting position.
6. Fix the specimen for Izod test to the support.
7. Release the pendulum as before. The hammer strikes the specimen.
8. Note the reading against the pointer. This gives the energy absorbed by the specimen.

OBSERVATION:

Length of the specimen = mm
Effective cross-sectional area = mm
Energy absorbed by the specimen = J
TABULATION:


Sl .No

Effective cross-sectional
area ( mm
2
)
Energy absorbed by the
specimen ( J )
Impact strength
(J / mm
2
)





CALCULATION:

Energy absorbed by the specimen
Impact strength = -------------------------------------------------------------- J/mm
Effective cross-sectional area
RESULT:

Impact strength of the given specimen = J/mm





7. TENSION TEST ON MILD STEEL BAR

AIM:
To study the behaviour of a mild steel specimen under tension when tested to destruction
and also to determine the following.
i) Youngs modulus ii) Yield stress iii) Ultimate stress iv) Breaking stress
v) Percentage elongation in length vi) Percentage reduction in area.

APPARATUS REQUIRED :
1. Universal testing machine
2. Extensometer
3. Vernier caliper
4. Scale
DESCRIPTION OF MACHINE :
The machine consists of two units namely
1. The loading unit
2. The control unit.
The loading unit consists of a robust base. The main hydraulic cylinder is to be fitted in the
centre of the base and the piston slides in the cylinder. It consists of a lower table, which is
connected to the main piston through a ball and ball seal joint and two cross heads. The lower
table and the upper cross head assembly moves up and down with the main piston.
The main units in the control panel are
1. The oil tank which contains the hydraulic oil.
2. The pump which assures a continuous high pressure non - pulsating of current for the
smooth application of load on the specimen.
3. Two valves one at the right hand side and the other at the left side are used to control the
oil flow in the hydraulic system and Dynamometer is a unit which measures and indicates
the load. It is a pendulum dynamometer consisting of a cylinder in which the piston
reciprocates.
4. The displacement of the piston causes the pendulum to deflect and this deflection
represents the measurement of the load on the specimen.

THEORY:

Within the elastic limit for ductile materials, stress bears a constant ratio with the applied
stress. When the test sample is tested by varying the stress in UTM at the time of yield, the point
steps for a moment. This will be followed by the scaling off from the surface of the specimen.
Further increase in load will be the ultimate load and this will be shown by the dummy indicator
on the load scale and the breaking load will be shown by the active indicator needle when the
specimen fails.
PROCEDURE :
Initial adjustment: Before the testing, adjust the pendulum weight according to
the capacity of the test. Adjust the corresponding range on the dial with the range - adjusting
knob.
1. Measure the diameter of the specimen in two directions perpendicular to each other
atleast at three places on the bar and take the average .
2. Mark the gauge length on the bar.
3. Select the appropriate measuring range by placing proper weights on the Pendulum of the
U . T . M.
4. Fix one end of the mild steel bar in the clamping jaws of the U. T. M
5. Now adjust the lower head to the required distance and grip the other end of the mild
steel bar in the clamping jaws in it.
6. Clamp the extensometer.
7. Apply the load gradually by opening the right control valve and note the corresponding
extensometer reading.
8. At a particular stage there will be a pause in the increase of load. The load at that point is
noted as yield point load.
9. After the pointer reaches the maximum, there will be a sudden drop in the load and this
is recorded as ultimate load.
10. A neck is formed at the center of the specimen and continue the loading with a dummy
pointer accompanying the load pointer until the mild steel bar breaks. Note the breaking
load at the time of fracture.
1. Now close the right control valve. Remove the specimen from the machine.
2. Measure the final length and the diameter of the mild steel bar.
3. Calculate the stress and strain for each reading and plot a graph. Slope of the line gives
the Modulus of Elasticity.

OBSERVATION:
Diameter of the specimen (D) = mm
Gauge length of the specimen (L) = mm

Neck diameter after fracture(D
1
) = mm


Final gauge length after fracture (L
1
) = mm

Yield load N
Ultimate load = N
Breaking load N

TABULATION :


Sl. No

Load


Extensometer reading
mm

Strain

Stress
N/mm
2


Youngs
Modulus
N/mm
2
Kgf N Dial I Dial II Mean
1.
2.
3.
4.
5.
6.
7.
CALCULATION:
Initial cross-sectional area (A) = mm

Final cross-sectional area (A
1
) = mm

% reduction in area = Initial area - Final area
--------------------------------- X 100 %
Initial area

Final length - Initial length
% Elongation in length = -------------------------------- X 100 %
Initial length

Yield load
Yield stress = -------------------------
Initial cross-sectional area


Ultimate load
Ultimate stress = --------------------------- N/mm
Initial cross-sectional area




Breaking load
Nominal Breaking stress = ------------------------------ N/mm
Original area of crass section
Breaking load
Actual Breaking stress = ------------------------------ N/mm
Final area of cross section

Axial stress
Youngs modulus = ----------------- N/mm
Axial starain

RESULT :

1. Young s modulus =

2. Yield stress =

3. Ultimate stress =

4. Nominal breaking stress =

5. Actual Breaking stress =

6. % reduction in area =
7. % elongation in length =




8. ROCKWELL HARDNESS TEST

AIM :
To find the Rockwell hardness number for the given materials.
GENERAL :
The Rockwell hardness test is of the static indentation type and the Rockwell hardness
number is based on the additional depth to which a penetrator is driven by a heavy load beyond
the depth to which a penetrator has been driven by a definite light load .The following indentors
are used in Rockwell hardness tester .
a ) Diamond cone indentor with a top angle of 120
0
.
b ) Steel ball of diameter 1/ 16 .
Load range : 60 , 100 , 150 kg.

APPARATUS REQUIRED:
1. Rockwell hardness testing machine
2. Stop watch
PROCEDURE :
1. Put the weights on plunger of dash-pot according to the Rockwell scale required by
turning the Load selector disc, the respective figure of weight will be visible in the
window.
2. Keep the lever at position A.
3. Place the specimen securely on the work table .
4. Turn the hand wheel clockwise so that the specimen will push the indentor and show a
reading on dial gauge as small pointer at 3. The long pointer automatically stops at 0
on black scale. (i.e ) B 30 on red scale .
5. Turn the lever from position A to B slowly so that the total load is brought into action
without any jerks.
6. When the long pointer of dial gauge reaches a steady position, take back the lever to A
position slowly.
7. Read off the figure against the long pointer. This gives the Rockwell hardness number
8. Turn back the hand wheel and remove the specimen from the machine. Carry on the
same procedure for further specimens.

TABULATION :

Sl . No Specimen Load
kg f
Indentor Scale Rockwell hardness number

Trial 1 Trial 2 Trial 3 Mean











RESULT :

The Rockwell hardness number for








9. BRINELL HARDNESS TEST
AIM :
To determine the Brinell hardness number for the given specimens.
APPARATUS :
1. Brinell hardness testing machine.
2. Microscope.
DESCRIPTION OF MACHINE :
The machine consists of a J frame, main lever, hanger, elevating screw, loading
unloading mechanism and damper system. The load is applied on the specimen through ball
holder, it is effected through a lever mechanism.
The main lever carries three male vees, one for hanger, second for spindle shaft and third
for pivot vee. The elevating screw can be moved up and down by rotating the hand wheel. The
five detachable weights, each equivalent to 500 kg and to be made use of for application of
desired load in addition to the bottom weight equivalent to 500 kg. The operating lever is
provided for loading and unloading.
PROCEDURE :
1. Polish the surface of the specimen.
2. Place the specimen on the worktable.
3. Keep the operating lever in horizontal position.
4. Turn the hand -wheel in clockwise direction so that the specimen touches the ball
indentor.
5. Lift the operating lever from horizontal position upwards slightly after which it rotates
automatically.
6. Wait till the lever becomes standstill.
7. Bring the lever back to horizontal position.
8. Turn back the hand wheel and remove the specimen from the machine. Carry on the
same procedure for further specimens.
9. Measure the diameter of impression by Brinell Microscope.
10. Find the Brinell hardness number using the formula

FORMULA:




P
Brinell Hardness Number = --------------------------------
D / 2 [ D - (D
2
- d
2
) ]
Where P - load in Kgf
D - Dia. of indenter in mm
d - Dia. of indentation in mm
For Steel , P = 30 D
2

For Brass , P = 10 D
2

For Aluminium, P = 5 D
2

OBSERVATIONS :
Diameter of indentor , D =
Diameter of indentation, d =








TABULATION :



Sl . No Specimen Diameter of
indentor D
(mm)
Load
kgf
Diameter of impression
(mm)
Brinell
hardness
number
Trial
1
Trial
2
Trial
3
Mean




RESULT : Brinell hardness number for the given specimens =















11. LOAD MEASUREMENTS USING LOAD INDICATOR & LOAD COILS
Aim:
To study the load measurements using load indicator & load coils.
Apparatus Required:
Proving ring with strain gauge boarded digital force indicator & necessary
weights.
Procedure:
1. Dial Gauge will show o (Zero) when there is no load in the plan.
2. Apply the Load in the pan, note down the deflection shown at the dial gauge.
3. 1kg =10 kg (beam length is 1 mtr)
4. Max .Load to be applied is 25 kg =250 kg
Tabulation:
SLNO Weight in (kgs) Indicator
Reading (kgf)
Force: Mass x
Acceleration .
Deflection in
(mm)
01
02
03
04
05
06
07

Graph :
1.Mass Vs indicator reading .
2. Mass Vs deflection in micros.
3. Indicator reading Vs deflection in (mm)

Result:
The load measurements using load indicator & load coils is studied.