REFLECTIVE WRITING-1

Mech 6511

Submitted to:- Submitted By:-

Prof. Dr. TSZ HO KWOK Pramod Kumar Pakalapati
ID:40012812
Contents:
Introduction
Properties of materials
Design of proposed material
Stress strain relation
Hardness
Experienced examples
Temperature Effects
Experienced examples
Summary

Introduction
Manufacturing is the way toward changing over some material into a product.
Everything around you, each thing you utilize, is fabricated. Every object you
utilize is comprised of segments, each of which used exceptionally specific
equipment to make it. Main concepts of manufacturing is, will pick up the capacity
to recognize issues with items, and propose interchange materials/forms that could
enhance them. Ought to have the capacity to assemble a model of a procedure, and
perform examination that will show the ideal conditions for the utilization of the
procedure under some predefined criteria. Producing alternates under a wide range
of financial frameworks.

Toward one side, assembling is continuous. At the flip side, it is exceedingly

intermittent. From the design point of view should be versed both products design
and also equipment process.

For any process of manufacturing we should expect the precise shape or output,
but it happens rarely that depends on the material properties. So by considering all
the properties we should design the process for manufacturing. It should cover lot
more areas for fulfilling to achieve final product.

We should relatethe required structure, material properties and processing.

Design Requirements:
Design requirements from manufacturing scenario are we should estimate the
difficulty in making, required number of items, techniques of manufacturing etc.

Selection of materials is the big thing in manufacturing, we should finalize the

materials as per required whether metallic or nonmetallic.

Metallic materials that do not have iron as their major ingredient are considered to
be nonferrous metals. There are several materials comes under the nonferrous
metals.

Zinc, tin and lead are low melting point with below 427C, which are majorly
using in die casting.

Non-metallic materials incorporates chemical compound and nonmetals that are

available in steel and alloys. They are the result of concoction responses, physical
impacts, and pollution that happens amid the dissolving procedure. These
incorporations are ordered by origin as either endogenous or exogenous.

We should consider three types in properties of material

1) Mechanical properties of materials

2) Physical properties

3) Chemical properties

Mechanical properties:
Mechanical properties are valuable to gauge how parts will carry on when they are
subjected to mechanical loads. Specifically, we are intrigued to know when the part
will come up fail (i.e. break, or generally change shape/size to leave detail), under
various conditions. These incorporate stacking under: Tension, compression,
torsion, bending. We interest on their hardness, and how these properties change
with temperature.
Basic mechanical properties are
Strength: Capacity to resist the utilization of loads without disappointment.
Stiffness: Resistance to deformation of the object under given load in an elastic state.

Hardness: Resistance to abrasion.

Elasticity: It is the flexibility if material shape, when the load is applied on the
material, ability to deform without taking a permanent shape when the load is
released.

Plasticity: Deformation of the object beyond the elastic range.

Static mechanical properties

Static force is defined as steady force acting on a material. Static mechanical
properties are related to the strength and hardness of a material. The strength of a
material is its ability to withstand a force or load without breaking.
Stress and strain :
Stress is defined as intensity of forces which are distributed internally.

Load acting and been transmitted materials cross section.

Strain is basically defined as change in length per unit length.

Types of stresses:
a) Tensile stress: Length of the material leads to increase in tensile direction.
b) Compressive stress : Length of the material shortening
c) Shear stress: Shearing stress is a constrain that causes layers or parts to slide
upon each other in inverse bearings.
 Fig: Tensile, compressive and shear stress

If we plot the stress versus strain, for most materials, the graph looks something like the following.

Fig: Stress-strain curve in tensile test

Elastic deformation: If the load released the material will back to the original
form with in elastic deformation range.
Linear elastic range: in the initial part of the graph, strain varies linearly with
stress.
Plastic range: At the point when the material is extended past the flexible range,
the atomic structure rearranges and it experiences some lasting extending; the
stress at which the distortion first gets to be distinctly plastic is the Yield Stress.
Ultimate Tensile strength (UTS):As we continue expanding the heap in the
plastic range, sooner or later, the material all of a sudden loses strength, and some
cross area turns out to be extremely limited and lengthens uninhibitedly (necking).
The maximum stress that it could withstand is the UTS.

fig: stress-strain diagram for compression test

True stress and strain curve:
From the previous section , beyond the elastic limit their will be interpretation of
engineering stress and strain curve, since the dimensions will face changes from
their actual values.Using the true stress t= P/A rather than the engineering stress
e=P/A0 can give a more direct measure of the materials response in the plastic
flow range. A measure of strain frequently utilized as a part of conjunction with the
true stress takes the heap of strain to be the incremental increment in displacement
dL separated by the present length L.

Tensile and compressive test:

Tensile test:
Tensile test is used to study the relationship between stress and strain and
also used for determining static properties of materials.
Hypothetically, this is a good test in light of the clear effortlessness with
which it can be performed and in light of the fact that the uniaxial loading
condition brings about a uniform stress distribution over the cross section of
the material.
 In reality, a tensile load is hard to accomplish in light of misalignment of the
material and some bending normally comes about. This is not genuine when
testing malleable materials like copper in which nearby yielding can
redistribute the stress so consistency exists.
In general when the tensile test applies length of the material will increase
and diameter will get decrease.
Compressive test:
During the compressive test it will be difficult because the material gets
start bending.
Most materials are much stronger in compression than in tension. If a
cylindrical sample is subjected to compression at the two ends, it will
usually fail by a process called buckling.

Experienced examples for both tests

In the event that one pulls on a material until it breaks, one can discover
loads of data about the different qualities and mechanical practices of a
material. In this virtual examination we will look at the elastic conduct of
three diverse composite fiber materials. They have comparative uses
however altogether different properties.
Main applications for compression test are measuring the flexural
strength of sheet construction material and insulation boards.
Compression tests on car seat safety harnesses

Static testing methods:

Applications of the test: It can perform tension, compression, bend and folding,
shear and static cyclic testing is specifically suitable for testing of metals,
fasteners, construction materials and other components.
 Fig: Static test machine for tension and compression test

Relationship between tensile test and compression test

Even though between both curves will be different.
On account of plastics tensile testing, the test is pulled separated to
measure elasticity and different properties including stiffness and yield
strength
Compression test of polymer materials are secured which indicates the
kind of compressive plates and deflectometer utilized. The test is put
between compression test platens until the cell structure falls flat or bursts.
Shear stress and shear strain:
Shear stress is the proportion of shear force connected on a surface
separated by the area of the surface. Shear stress is an tangential force
applied on surface, that is the force connected along the surface.
Shear strain is equivalent to the length of transverse deformation of the
question at its greatest partitioned by the opposite length in the plane of
force application. It can be considered as tangent angle by which two
opposite lines have change on utilization of shear force on a plane opposite
to one of the lines.

Ductility and brittleness in tensile test

Ductility is the capacity of a material to withstand tensile stress when it is

connected upon it as it experiences plastic deformation.
Whereas Brittleness is the inverse of ductility as it alludes to the capacity of
materials to break into endless supply of ductile compel with no
prolongation or plastic deformation.
Brittle material:
Give us a chance to expect that there is a microcrack in a brittle material, suppose a
ceramic. At the point when a tensile load is applied, the cracks spreads quickly on
the crack tip plastic zone in such a material is too little.
Hardness test:
There is no precise definition of hardness. Generally it defined as "resistance to
plastic twisting under load". Under this definition, it is measured by the lasting
deformation on the surface of the material being tried, when subjected to a
standard stacking.
Most common tests for engineering materals are Brinell, Rockwell and Vickers
tests. The figure below shows how the test works.

Brinell hardness test:

Brinell hardness test is used to test materials having rough or course surface e.g.,
casting and forging. It can be use very high test load upto 3000 kgf and a 10mm
wider.

Effects of temperature:
In several cases hardness varies with temperature difference. In much industrial
manufacturing process, temperature plays vital role. Depend upon the temperature,
material properties may vary and material may rupture. Brittle , ductility and
hardness of the material depends on temperature variation.

Experienced example:
From a boiler point of view, by changing of temperature from lower to higher and
vice versa. results rupture of tubes may occurs. Considering 600MW thermal
powerplant, the maximum mainsteam temperature should maintain 540C, but
depending upon the load and and supply of coal, temperature may vary. When the
material exceeds its properties, then it results heavy loss. It shows that depend
upon temperature material ductility and brittleness may effect.

Recrystallization:
At the point when temperature is raised, the new, grains and become inside the old
distorted grains and furthermore at the grain limits. This replaces the mutilated
grains delivered by strain hardening. The metal's mechanical properties return to
their unique, more ductile and weaker state.
Summary:
For any manufacturing process to produce a desired material or product,
selection of material is crucial. During the design of the process flow we
should consider all the basic properties of materials and total estimation cost.
And also we discussed the stress and strain relation for material and applied
load.
After completing the manufacturing process we should proceed to the
material test such as brittle, ductile and hardness test.
In my point of view we should test the hardness, brittleness of the raw
material, by that we can save our time and cost of production.