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Transcript of 3RD SEM - MT LAB

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, R.V. College of Engineering, Bangalore 59.

Department of Industrial Engineering and Management

M T R LT ST GL B A E IA E IN AR.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 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 SUBJECT CODE: MEL37 A CLASS MARKS: 25 No. of Class 01 01 01 01 01 01 01 01 01 01 01 01 01 13 Class & Test Marks 20 20 20 20 10 20 20 20 10 20 10 10 50 250

KEY MT Materials Testing Expt. S Study Expt. D Demonstration Expt.

Material Testing lab Manual

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

EVALUATION SCHEME: CLASS MARKS (Reduced to 25) Proposed by: D.Venugopal setty. Shobha N S = Class work total + Test Marks 10 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

Material Testing lab Manual

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

Material Testing lab Manual

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

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.

Material Testing lab Manual

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

EXPERIMENT No. MT01

TENSION TEST ON DUCTILE MATERIALAIM: - 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

Material Testing lab Manual

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

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

Material Testing lab Manual

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

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 SKETCH OF THE SPECIMEN:Shoulder

d

D

l1 l L

Material Testing lab Manual

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