Mechanics of Materials Lab

Fall 2018

Lecture 1
(Material Testing Lab)
By: Engr. Hilal Yousafzai
Hilalyousafzai070@gmail.com

Department of Mechanical Engineering, IIU

Islamabad
 Lab outline

1. Study of Material testing Lab.

2. Study of universal testing m/c

3. Tensile test on UTM for a mild steel specimen.

4. Compression test on cement mortar cube

5. Shear test on mild steel specimen

6. Torsion test on ductile steel, Cast iron & brass.

 Book Recommended:

1. Mechanics of Materials by F.P Beer & ER Johnston

2. Mechanics of Engg Materials by FV Warnock P.P Benham &

R.J Crawford.
 Marks Distribution:

Assignments + Project + Quiz (25%)

Attendence (10%)

Viva Exam (15%)

Final Exam (50%)

Total 100%
Lets begin…..
mechanics of materials?

Strength of materials, also called mechanics of

materials, deals with the behavior of solid objects
subject to stresses and strains.

In mechanics of materials, the strength of a material is its

ability to withstand an applied load without failure or plastic
deformation.
 Materials
Testing
• Mechanical properties are obtained by mechanical
testing.
• Mechanical testing is used for developing design data,
maintaining quality control and providing data in failure
analysis.
 cont,.

 Mechanical testing is usually destructive and requires test

specimens of the material to be machined or cut to the
specific shape required by the test method.
 Mechanical
Properties

∗ Describe material when a force is applied to

it.
∗ Determined through testing, usually
involving destruction of material.
∗ Extremely important to consider in design.
Types of mechanical
properties

a) Ductility
b) Toughness
c) Brittleness
d) Hardness
e) Plasticity
f) Elasticity
g) Strength
 Ductility

∗ Ductility is a solid material's ability to deform

under tensile stress; this is often characterized
by the material's ability to be stretched into a
wire.
Tensile test of an
AlMgSi alloy
The local necking and the cup and
cone fracture surfaces are typical for
ductile metals.
Schematic
appearance of
round metal bars
after tensile testing.
a) Brittle fracture
b) Ductile fracture
c) Completely ductile
fracture
 Toughness
• Toughness is the ability of a material to absorb energy
and plastically deform without fracturing
• Material toughness is defined as the amount of energy per
volume that a material can absorb before rupturing.
• It is also defined as the resistance to fracture of a material
when stressed.
• Toughness requires a balance of strength and ductility.
 Brittleness

∗ A material is brittle if, when subjected to stress, it

breaks without significant deformation (strain).
∗ Brittle materials absorb relatively little energy prior to
fracture, even those of high strength.
∗ Breaking is often accompanied by a snapping sound.
Brittle materials include most ceramics and glasses
(which do not deform plastically) and some polymers,
such as PMMA and polystyrene.
∗ Many steels become brittle at low temperatures (see
ductile-brittle transition temperature), depending on
their composition and processing.
Brittle fracture in cast iron tensile test
pieces
Graph comparing stress-strain curves
for ductile and brittle materials.
 Hardness

∗ Hardness is the degree of resistance to

indentation, penetration, abrasion and wear.
∗ Indentation hardness measures the resistance of a
sample to permanent plastic deformation due to a
constant compression load from a sharp object; they
are primarily used in engineering and metallurgy
fields.
∗ Common indentation hardness scales are
Rockwell, Vickers, Shore, and Brinell.
 Plasticity

 Plasticity is the tendency of a material to undergo

permanent deformation underload.
 Elasticity

 Elasticity (or stretchiness) is the physical property of

a material that returns to its original shape after the
stress (e.g. external forces) that made it deform.
The relative amount of deformation is called the
strain.
 Strength

 Strength is the ability of a material to withstand

various loads to which it is subjected during a test or
service.
 Materials Testing

 2 types of materials testing:

a) Destructive test
-results in the part being destroyed during the
quality control testingprogram.
b) Non destructive test
- is done in such a manner that the usefulness of the
product or part is not damaged or destroyed.
 Non Destructive Test

 Non destructive inspection techniques enable

inspectors to check properties critical to the safe
performance of metal parts without causing damage
to the parts themselves.
 This test is concerned with testing for cracks and
flaws
 Types of non destructive test

a) Dye penentrant test

b) Radiographic test
c) Magnetic particle test
d) Ultrasonic test
 Dye Penentrant Test

 It is easy to use and economical.

1) The specimen is coated with a red liquid dye which
soaks into the surface crack or flaw.
2) The liquid is then washed off and the part dried.
3) Flaws and cracks show up red against the white
background of the developer.
Cracks in aweld
 Radiographic test

 This test involves passing gamma rays (X-rays)

through a part to detect flaws in the metal.
 The developed film has an image of the internal
structure of thepart.
 A defect will show up on the film as a dark area.
 X-rays are very sensitive and are capable of inspection
any thickness of almost any kind of materials.
 Magnetic particle test

 This test is used to detect flaws on or near the surface of

iron-based metals.
1) The part is first magnetized.
2) It is then either dusted with fine iron powder or coated
with a solution of iron particles.
3) Flaws in the workpiece cause the lines of magnetic force
to become distorted and break through the surface.
4) There they attract concentrations of the iron particles,
which reveal defects in the metal.
Concentration of the iron particle
shows defect in themetal
 Ultrasonic test

 This test use ultasonic sound waves to detect cracks

and flaws in almost any material that can conduct
sound.
 Sound waves can also be used to measure the
thickness from one side of the material.
 Cont.

 The human ear can hear sound waves with

frequencies ranging from 20 to 20,000 Hertz.
 Sound waves that vibrate with a frequency greater
than 20,000 Hz are inaudible and are called ultrasonic.
 Cont.

 These high frequency sound waves are produced by a

piezoelectric transducer.
 The transducer is electrically pulsed and then vibrates
at its own natural frequency.
1) In order to operate, the transducer must be joined to
the piece being tested by a liquid coupling such as a
film of oil, glycerin or water.
 Cont.

2) The high frequency sound waves are transmitted

through the material.
3) The flaws reflect the sound waves and are detected
on an oscilloscope.

There is no size limitation on work that can be

tested by ultrasonic test.
Ultrasonic Test
DESTRUCTIVETEST
 Destructive Testing

• Destructive testing is a costly and time consuming

technique. A specimen is selected at random from a
large number of pieces.
• Two types of destructive test:
a) Hardness test
b) Impact test
 Hardness Test

• Indentation hardness measures the resistance of a

sample to permanent plastic deformation due to a
constant compression load from a sharp object.
• types of hardness test:
a) Rockwell
b) Brinell
 Rockwell Hardness Test

 The Rockwell hardness tester functions according to

the depth of penetration made in metal by a specific
kind of penetrator point forced by a given load.
Rockwell Hardness Tester
 Cont.

 The Rockwell hardness test uses two loads that are applied
sequentially.
 A minor load of 10 kg is applied that helps seat the indenter
and remove the effect of surface irregularities.
 A major load which varies from 60 kg to 150 kg is then
applied.
 The difference in depth of indentation between the major
and minor loads provides the Rockwell hardness number.
 This number is taken directly from the dial on the machine.
 Brinell Hardness Tester

 Brinell hardness test use a machine to press a 10 mm

diameter, hardened steel ball into the surface of the
test specimen.
 This machine applies a load for a specific period of
time and causes an indentation that is used to
calculate hardness.
Cont.
 Cont.

 The load applied to the steel ball depends on the type

of metal undertest.
 The load is usually applied for 10 to 15seconds.
 The diameter of the indentation is measured to ±0.5
mm using a low magnification portable microscope.