Experiment #1

EGR 320L
07Oct2017

Mechanical Engineering Lab to Test Maximum Weight That Can Be Supported by iPod Earbud
Wires

Introduction

The purpose of this experiment is to see what maximum weight can be applied to a set of iPod Earbuds
before they break and to compare the data found to data gathered from aluminum, steel and
polycarbonate sample data. The comparison will show the individual tensile strength of each sample in
comparison to the composite of all three combined in the iPod Earbud wire.

In this experiment force, stress, elongation and strain data will be gathered and calculated to determine
the modulus of elasticity of the material

Experimental Procedure

Each sample of aluminum, steel, polycarbonate, thick and thin wire have been recorded on an ADMET
Tensile Testing machine displaying Force in Newton and Elongation in millimeters. The thick and thin
wires represent the composite of the individual samples representing thin and thick iPod Earbud wires.

All samples of aluminum dog-bone (two), steel dog-bone (one), polycarbonate dog-bone (two),
thin wire (one) and thick wire (one) were tested in the ADMET Tensile testing machine. The machine
pulled all samples at a constant rate while the applied force (in Newton) and elongation (in millimeters)
were measured and recorded until broken. This data was then used to calculate stress and strain on all
samples. This is then comprised into a graph for better visual comprehension.

Data

The following tables and graphs show the raw data collected from the ADMET device and the initial
metrics recorded for the samples. All data was converted to millimeters.

Aluminum "dog-bone" Sample Dimensions (#1 and #2)

Length 80mm
Width 4.0mm
Thickness 0.0762mm

Steel "dog-bone" Sample Dimensions

Length 80mm
Width 4.0mm
Thickness 0.0762mm
Polycarbonate "dog-bone" Sample Dimensions (#1 and #2)
 Length 80mm
Width 4.0mm
Thickness 0.381mm

Thick Wire Sample (iPod) Dimensions

Length 80mm
Diameter 2mm

Thin Wire Sample (iPod) Dimensions

Length 80mm
Diameter 1.5mm

Aluminum "dog-bone" Sample Data #1

Elongation in millimeters
Force in Newton (N) (mm)
0 0
3.76 0.02
7.96 0.042
23.33 0.127
30.76 0.169
36.84 0.222
44.9 0.347
49.75 0.537
51.88 0.837
52.7 1.246

Aluminum "dog-bone" Sample Data #2

Force in Newton Elongation in millimeters

(N) (mm)
0 0
5.46 0.031
7.83 0.043
15.46 0.096
20.74 0.109
29.57 0.156
30.86 0.171
38.34 0.234
45.08 0.382
 53.25 1.136

Steel "dog-bone" Sample Data

Elongation in millimeters
Force in Newtons (N) (mm)
0 0
20.92 0.05
35.53 0.085
43.18 0.105
61.84 0.147
75.22 0.179
105.62 0.254
160.98 0.41
200.83 0.57
238 1.446

Polycarbonate Plastic "dog-bone" Sample Data #1

 Elongation in millimeters
Force in Newton (N) (mm)
0 0
11.71 0.264
40.52 0.987
70.91 2.241
80.2 3.063
85.13 3.8
87.72 5.642
72.11 11.02
72.95 14.558
75.59 24.86
76.71 30.49
77.12 32.155

Polycarbonate Plastic "dog-bone" Sample Data #2

Force in Newton Elongation in millimeters

(N) (mm)
0 0
13.32 0.317
36.07 0.067
49.85 1.257
62.01 1.702
87.73 3.69
90.2 4.452
78.56 8.025
75.94 10.626
76.55 14.647
78.12 26.315
78.11 33.215
Thin iPod Wire Sample Data

Elongation in millimeters
Force in Newton (N) (mm)
0 0
19.91 0.569
40.156 0.935
55.012 1.204
59.24 1.27
68.77 1.415
82.27 1.651
95.1 1.861
101.07 2.009
5.41 5.211
5.54 13.355
7.9 20.712

Thick iPod Wire Sample Data

Force in Newtons Elongation in millimeters

(N) (mm)
 0 0
7.13 0.261
56.68 0.891
71.6 1.027
88.06 1.237
102.16 1.386
119.8 1.577
129.34 1.672
136.72 1.767
162.64 2.075
184.91 2.354
196.87 2.528
207.36 2.68
225.31 3.012
26.31 9.403
24.94 14.072
30.35 21.7
34.13 31.171
35.32 45.693
23.165 64.362
Results & Discussion

Utilizing the data gathered (Force in Newtons) and the known dimensions, the stress ( = /)
which is the applied force divided by the cross-sectioinal area of the sample, and the strain ( = /)
which is the elongation of the sample divided by its original length.

Using the results of stress and strain equations, Hookes Law states that the stress ( ) in a material is
proportional to the strain ( ). The constant of proportionality E is called the modulus of elasticity or
Youngs Law. Hookes law applies if the material is not deformed beyond its ability to resume its original
size after the force is removed. (E= / or = E )

Since stress is proportional to strain, the elastic range will be represented by a straight line in the graph.
The slope of the line created in the elastic range by plotting the data will determine the modulus of
material. (E= / )

Cross sectional areas of metal and plastic samples are calculated by A=width x thickness and the wires
2
calculated by A= x 2 or A= 4
.

The following is the calculated cross-sectional Area calculations of each sample along with dimensions.

Aluminum and Steel Dimensions

 Length 80mm 8.0102m
Width 4.0mm 4.0103m
Thickness 0.0762mm 7.62105m
Area 0.305mm 3.05104m

Polycarbonate "dog-bone" Sample Dimensions (#1 and #2)

Length 80mm 8.0102m

Width 4.0mm 4.0103m
Thickness 0.381mm 3.81104m
Area 1.52mm 1.52103 m2

Thick Wire Sample (iPod) Dimensions

Length 80mm 8.0102m

Diameter 2mm 2.0103m
Area 3.14mm 3.14103 m2

Thin Wire Sample (iPod) Dimensions

Length 80mm
Diameter 1.5mm 1.5103m
Area 1.77mm 1.77103 m2

Stress calculations of samples utilizing equation = /

Strain calculations of samples utilizing equation = /

Aluminum "dog-bone" Sample Data #1 Stress and Strain

=force/area =/L
Stress (Mpa) Strain (mm/mm)
0.00 0
12.33 0.00025
26.10 0.000525
76.49 0.0015875
100.85 0.0021125
120.79 0.002775
147.21 0.0043375
163.11 0.0067125
170.10 0.0104625
172.79 0.015575
Aluminum "dog-bone" Sample Data #2 Stress and Strain

=force/area =/L
Strain
Stress (Mpa) (mm/mm)
0.00 0
17.90 0.0003875
25.67 0.0005375
50.69 0.0012
68.00 0.0013625
96.95 0.00195
101.18 0.0021375
125.70 0.002925
147.80 0.004775
174.59 0.0142

Steel "dog-bone" Sample Data Stress and Strain

=force/area =/L
Strain
Stress (Mpa) (mm/mm)
0.00 0
68.59 0.000625
116.49 0.0010625
141.57 0.0013125
202.75 0.0018375
246.62 0.0022375
346.30 0.003175
527.80 0.005125
658.46 0.007125
780.33 0.018075

Polycarbonate Plastic "dog-bone" Sample Data #1 Stress and Strain

=force/area =/L
Strain
Stress (Mpa) (mm/mm)
0.00 0
7.70 0.0033
26.66 0.0123375
46.65 0.0280125
52.76 0.0382875
 56.01 0.0475
57.71 0.070525
47.44 0.13775
47.99 0.181975
49.73 0.31075
50.47 0.381125
50.74 0.4019375
0.00 0

Polycarbonate Plastic "dog-bone" Sample Data #2 Stress and Strain

=force/area =/L
Strain
Stress (Mpa) (mm/mm)
0.00 0
8.76 0.0039625
23.73 0.0008375
32.80 0.0157125
40.80 0.021275
57.72 0.046125
59.34 0.05565
51.68 0.1003125
49.96 0.132825
50.36 0.1830875
51.39 0.3289375
51.39 0.4151875

Thick iPod Wire Sample Data Stress and Strain

=force/area =/L
Strain
Stress (Mpa) (mm/mm)
0.00 0
2.27 0.0032625
18.05 0.0111375
22.80 0.0128375
28.04 0.0154625
32.54 0.017325
38.15 0.0197125
41.19 0.0209
43.54 0.0220875
51.80 0.0259375
 58.89 0.029425
62.70 0.0316
66.04 0.0335
71.75 0.03765
8.38 0.1175375
7.94 0.1759
9.67 0.27125
10.87 0.3896375
11.25 0.5711625
7.38 0.804525

Thin iPod Wire Sample Data Stress and Strain

=force/area =/L
Strain
Stress (Mpa) (mm/mm)
0.00 0
11.25 0.0071125
22.69 0.0116875
31.08 0.01505
33.47 0.015875
38.85 0.0176875
46.48 0.0206375
53.73 0.0232625
57.10 0.0251125
3.06 0.0651375
3.13 0.1669375
4.46 0.2589
In the strain and stress graph of the metal samples there is a large difference between the elasticity and
breaking point of the steel sample and the aluminum samples.

To find Youngs Modulus (E) it can be calculated by dividing the tensile stress, by the strain in elastic
portion of the curve.

Calculate slope of elastic portion of the curve using E= slope of Line AB=

From Internet Sources listed in 6061 Aluminum Physical Steel properties

References properties
Density () 2.70 g/cm3 7.87 g/cc
Young's modulus (E) 68.9 GPa 200 GPa
Tensile strength (t) 124290 MPa (18.042.1 ksi) 415 MPa
Elongation () at break 1225% 1225% 10%
Poisson's ratio () 0.33 .303

Calculations from Sample Data Equation Young's modulus (E)

Aluminum Data Sample#1 26.100 49.714GPa
E=
0.0005250
 Aluminum Data Sample#2 96.950 49.717GPa
E=
0.001950
Steel Data Sample 0.346.30 109.070Gpa
E=
.0.0031750

The Youngs Modulus of elasticity is the slope of the straight line AB, E=

From the above graph it can be noted that the two polycarbonate samples are very similar.

To find Youngs Modulus (E) it can be calculated by dividing the tensile stress, by the strain in elastic
portion of the curve.

Calculate slope of elastic portion of the curve using E= slope of Line AB=

From Internet Sources listed Polycarbonate

Density () 31.201.22 g/cm3
Young's modulus (E) 2.02.4 GPa
 Tensile strength (t) 5575 MPa
Elongation () at break 1225% 80150%
Poisson's ratio () 0.33 0.37

Calculations from Sample Data Equation Young's modulus (E)

Polycarbonate Data Sample#1 52.760 1.4GPa
E=
0.03828750
Polycarbonate Data Sample#2 40.800 1.92GPa
E=
0.0212750

The thick and thin iPod wires are very similar even with differing diameters.

Calculations from Sample Data Equation Young's modulus (E)

Thick wire Data Sample#1 51.800 2GPa
E=
0.02593750
Thin wire Data Sample#2 53.730 2.3GPa
E=
0.02326250

Conclusion
In conclusion we can identify that the composite of both polycarbonate and metal in the thick and thin
iPod wire has a combined greater tensile strength higher breaking point than any of the sample
materials did on their own. It took over 225.31 N of force to break the thick wire and over 101.07 N of
force to break the thin wire. If we assume a 45 degree angle of the thin wire at the y junction, each thin
wire bears half the force of the thick wire. Taking the smaller of the force used to break the thick wire
or twice the force used to break the thin wire, we divide 202 N of force by the gravitational constant
9.81 m/s2 to get a weight of approximately 20.6 kilograms, or 45.42 lb. From recording the raw data
from the ADMET tensile strength machine and calculating stress and strain we have factual data to
support that an iPod is less likely to be destroyed by wire breakage excluding other extraneous data.

From these tests we've seen that metals have relatively low breaking points compared to plastics, and
are considerably less elastic with none of the polycarbonate samples and thick iPod wire breaking. Thick
iPod wire did not break at all except the metal interior wire snapping.

References

Introduction to Engineering Analysis

Data for aluminum (https://en.wikipedia.org/wiki/Ultimate_tensile_strength)

Data for Steel (https://www.ezlok.com/TechnicalInfo/MPCarbonSteel.html)

Data for polycarbonate (http://www.matweb.com/reference/tensilestrength.aspx)

Data for Polycarbonate (https://en.wikipedia.org/wiki/Polycarbonate)

Poissons Ratios (https://en.wikipedia.org/wiki/Poisson%27s_ratio)