Experiment 1 : Tensile Test Objective i. To estimate the stress () and strain () of the material. ii. To study the stress and strain behavior of the material using -diagram. iii. To study the various regions of the -diagram. iv. To determine the Young’s modulus or the Modulus of Elasticity. v. To study the ductile behavior of the material. Abstracts Tensile are fundamental for understanding properties of different material, and how they will behave under load. This experiment tested four different material, including steel, copper, aluminum, and copper alloy (brass). Each material was tested by using a pull tester and data was recorded. The data from each test was used to determine valuable material properties such as ultimate tensile strength, modulus of elasticity, and yield strength. Other calculated properties included true fracture strength, percent reduction of area, and percent elongation. These material properties were used for comparing the material to each other, and to define the material as brittle or ductile. The results of the tensile tests showed that the steel was the strongest material. It had the highest ultimate tensile strength (699 MPa), the greatest yield strength (684 MPa), and the largest true fracture strength (554.2 MPa). The copper had a higher yield (310 MPa) than the aluminum (292.1 MPa), a higher ultimate tensile strength (315 MPa), but a lower true fracture strength (165 MPa). All of the materials
To investigate the modulus of elasticity of various metal.
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Experiment 1 : Tensile Test
Objective
i. To estimate the stress () and strain () of the material.ii. To study the stress and strain behavior of the material using - diagram.
iii. To study the various regions of the - diagram.iv. To determine the Young’s modulus or the Modulus of Elasticity.v. To study the ductile behavior of the material.
Abstracts
Tensile are fundamental for understanding properties of different material, and how they will behave under load. This experiment tested four different material, including steel, copper, aluminum, and copper alloy (brass). Each material was tested by using a pull tester and data was recorded. The data from each test was used to determine valuable material properties such as ultimate tensile strength, modulus of elasticity, and yield strength. Other calculated properties included true fracture strength, percent reduction of area, and percent elongation. These material properties were used for comparing the material to each other, and to define the material as brittle or ductile.
The results of the tensile tests showed that the steel was the strongest material. It had the highest ultimate tensile strength (699 MPa), the greatest yield strength (684 MPa), and the largest true fracture strength (554.2 MPa). The copper had a higher yield (310 MPa) than the aluminum (292.1 MPa), a higher ultimate tensile strength (315 MPa), but a lower true fracture strength (165 MPa). All of the materials besides the brass proved to be ductile, especially the copper, which had a percent elongation of 9.6%. The brass sample averaged a percent elongation of only 3.1%.
Methodology
Stress and strain relationship
When a specimen is subjected to an external tensile loading, the metal will undergo elastic and plastic deformation. Initially, the metal will elastically deform giving a linear relationship of load and extension. These two parameters are then used for the calculation of the engineering stress and engineering strain to give a relationship as follow
σ= PAo
ε=Lf−Lo
Lo= δ
L0
Where, is the stress
is the strain
P is the external axial tensile load
Ao is the original cross-sectional area of the specimen
is the deformation of the specimen
Lo is the original length of the specimen
Lf is the final length of the specimen
Young’s modulus, E
During elastic deformation, the engineering stress-strain relationship follows the Hook's Law and the slope of the curve indicates the Young's modulus (E)
E=σε
Young's modulus is of importance where deflection of materials is critical for the required engineering applications. This is for examples: deflection in structural beams is considered to be crucial for the design in engineering components or structures such as bridges, building, ships, and others. The applications of tennis racket and golf club also require specific values of spring constants or Young's modulus values.
Figure 1: Stress-strain relationship under uniaxial tensile loading
Yield strength, y
By considering the stress-strain curve beyond the elastic portion, if the tensile loading continues, yielding occurs at the beginning of plastic deformation. The yield stress, σy, can be obtained by dividing the load at yielding (Py ) by the original cross-sectional area of the specimen (Ao ) as shown
σ y=P y
Ao
The yield point can be observed directly from stress-strain curve of the metals. At the yield point, the specimen continues to extend without a significant change in the stress level. Load increment is then followed with increasing strain.
Ultimate Tensile Strength
Beyond yielding, continuous loading leads to an increase in the stress required to permanently deform the specimen as shown in the stress-strain curve. At this stage, the specimen is strain hardened or work hardened if the load is continuously applied, the stress-strain curve will reach the maximum point, which is the ultimate tensile strength. At this point, the specimen can withstand the highest stress before necking takes place. This can be observed by a local reduction in the cross sectional area of the specimen.
Rupture Strength, rupture
After necking, plastic deformation is not uniform and the stress decreases accordingly until fracture. The rupture strength (σrupture) can be calculated from the load at rupture divided by the original cross-sectional area, Ao, as expressed
σ rupture=Prupture
Ao
Tensile ductility
Tensile ductility of the specimen can be represented as percentage of elongation or percentage of reduction in area as expressed in the equations given below
Percentage of Elongation=|Lf −Lo
Lo|x100 %
Percentage of Reduction∈Area=|A f −Ao
Ao|x 100 %
Where Af is the cross-sectional area of the specimen at fracture.
Fracture characteristics
Metals with good ductility normally exhibit a so-called cup and cone fracture characteristic whereas metal with low ductility appear a flat fracture surface as shown in figure below.
Necking starts when the stress-strain curve has passed the maximum point where plastic deformation is no longer uniform. This type of fracture surface signifies high energy absorption during the fracture process due to large amount of plastic deformation taking place, also indicating good tensile ductility. Metals such as aluminum and copper normally exhibit ductile fracture. For brittle metals, the fracture surfaces usually consist of flat.
Figure 2: Fracture characteristics
Apparatus
1. Universal Testing Machine2. Sample specimens of metal3. Vernier caliper
Figure 3: Universal Testing Machine
Figure 3a: Force display
Figure 3b: Elongation display
Figure 4: Sample specimens of metal
Procedure
1. The original length and diameter of four materials was measured by vernier caliper and readings were recorded.
2. The load frame of the upper part was adjusted to fit the test specimen inside the dial gauge.
3. The dial gauge was loosened and lowered it on the column and a test specimen was chosen and screwed tightly into the jaws of the machine.
4. The force display and elongation display of pull tester was adjusted back to zero reading.
5. The hand wheel was turn slowly to increment of 0.01mm for each elongation and the test specimen was observed.
6. The force applied and elongation was recorded base on the elongation display and force display from time by time until the test specimen reached its necking region and then fracture.
7. The true fracture force and final elongation were recorded.
8. The final length and diameter of four materials was measured by vernier caliper and readings were recorded.
9. Step 2 to step 8 was repeated by replacing each different material test specimen.
Results
Based on the observation, we can conclude that steel, copper and aluminum have good ductility and behave as ductile material as all of the sample specimen undergo necking process and exhibit a cup and cone fracture at the fracture surface. For brass, it behaves as brittle surface and appear a smooth fracture at the fracture surface.
Table 1: The original length, diameter and area for four materials
Materials Length, lo (m) Diameter, do (m) Area, A0 = π do4
4 (m2¿/x10−6
Steel 0.025 0.00505 20.03
Copper 0.025 0.00505 20.03
Aluminum 0.025 0.00505 20.03
Brass 0.025 0.00505 20.03
Table 2: The final length, diameter and area for four materials
Materials Length, lf (m) Diameter, d f (m) Area, A f = π d f2
4 (m2¿/x10−6
Steel 0.02642 0.00315 7.79
Copper 0.02739 0.00256 5.15
Aluminum 0.02705 0.00288 6.54
Brass 0.02578 0.00382 11.46
Table 3: The percent reduction of area, and the percent elongation for four materials
Materials Percent of elongation (%) Percent of reduction of area (%)
Steel 5.7 61.1Copper 9.6 74.3
Aluminum 8.2 67.4
Brass 3.1 42.8
Table 4: The yield strength, ultimate tensile strength, true rupture strength, and modulus of elasticity for four materials
Materials Steel Copper Aluminum Brass
Yield strength, σ y (MPa)
684 310 292.1 -
Ultimate tensile strength, σ u (MPa) 699 315 302 434.3
True rupture strength, σ r (MPa) 554.2 165 290 434.3
Modulus of elasticity, E (GPa) 63.1 40 150 37.4
Table 5: The percent error of modulus of elasticity for four materials
Materials Theoretical modulus of elasticity, ET (GPa)
Experimental modulus of elasticity, EE (GPa)
Percentage Error (%)
Steel 200 63.1 68.5Copper 117 40 65.8
Aluminum 69 150 117.4
Brass 114 37.4 67.2
Percentage error=¿
*The approximate theoretical values of Young Modulus are taken from Wikipedia.
Best Fit Line of Stress-Strain Curve of BrassWithin Proportional Limit
Stress, (kPa)
Strain, (mm/mm)
Young modulus of Brass, Eb = slope of stress-strain curve within proportional limit
E=y2− y1
x2− x1
Eb=269565.8137 x 103−0
0.0072−0=37.4397 x 109≈ 37.4 GPa
At fracture point,
δ=0.78 mm, Pr = 8.70 kPa
True Rupture Strength, σ r=P r
Ao= 8.7 x 103
20.03 x 10−6 ≈ 434.3 MPa
Discussion
1. After carrying out the experiment, we recorded the results. These results were then used to plot graphs of stress versus strain so that are able to see the relationships between each material.
2. As a general idea and based on the results obtained, we assume that copper and aluminum are ductile and brass as brittle. As we did not know the exact composition of the steel alloy, we took steel as a ductile material based on the shape of its curve in the stress strain graph. Harder steel alloys are usually more brittle than softer ones. However, although we take steel as a ductile material, it is still much stronger than other ductile materials (copper and aluminum).
3. From Table 4, which sums up most of the results of the experiment, we can see that Steel is the strongest material as it has the highest ultimate strength followed by brass, copper then aluminum. Steel also has the highest rupture strength. This is closely followed by brass aluminum then copper. Steel is the strongest because it is an alloy of iron. The carbon in steel provides a doping agent which increases strength in the crystal structure of the iron. This allows steel to become stronger and lighter than pure iron.
4. From the graphs, we see that copper has the highest ductility. As ductility increases with the maximums strain a material can handle, copper proves to be the most ductile material of the four. Ductile material can be stretch easily into wire due to their necking and yielding regions of their stress strain graph. On the other hand, Brass is the most brittle material as it does not take much elongation to rupture it.
5. Problems occurred when comparing Young’s Modulus. Between materials, aluminum was found to have the highest Young’s Modulus, higher than that of steel. This is theoretically impossible as Young’s Modulus is essentially a degree of stiffness. As Young’s Modulus increases, the material is stiffer.
6. As we can see from Table 5, we encountered extremely high percentage errors when comparing the theoretical and experimental Young’s Modulus. Errors are highly likely to have occurred here. Some of the possible error and problems faced are discussed below.
7. An important aspect of the experiment that was overlooked was the specimen alignment. A deviated alignment will significantly influence the results. If the alignment is off center, the rupture strength will be lowered considerably. This is because the experiment setup is no longer uniaxial. Unwanted side loading and
bending moments will cause the specimen to rupture with lower force. This affects brittle materials more than ductile materials. To counter this problem, we should always check the machine’s alignment before starting the experiment.
8. During the experiment, we found out that the hydraulics in machine were faulty. When increasing the force, we sometimes experienced a lost of control over the amount of the force we were adding. The wheel would lose its grip and rotate forward a great deal. The hydraulic system of the machine should be constantly checked and maintained in good condition.
9. Worn machine component also contributed to the error. For examples, worn out thread would lose their grip. The specimen may slip or break inside the gripped area. A dirty experimental setup will also affect the grip of the threads. The setup should be cleaned to prevent this error.
10. When carrying out the experiment, we did not take into account the decrease in diameter when the specimen is subjected to the load. We did not measure the gradual change in diameter so the stress is calculated using the same surface area. To accurately measure this decrease in diameter, we should change to an electronic setup.
11. To carry out the experiment, we used a shaped specimen that will concentrate the stress within the gage length. If the specimen is incorrectly machined, fracture could occur outside the gage length and result in strain errors. This is important because we want to avoid having a break or fracture within the area being gripped. We should always check the conditions of the specimen before the experiment.
12. The display of the force was also a problem. As the smallest division could only measure 0.5kN, we did not have the accuracy to control the force well. To solve this, we should use a computerized system to exert and measure the force.
13. Inaccurate reading of the specimen dimensions will also cause errors. Worn micrometers or calipers should be replaced and care should be taken when recording specimen dimensions. To prevent this error, a computer based test systems should be used to read the micrometer or caliper directly, thus eliminating data entry errors.
14. Parallax errors and human error also affected the results of the experiment. We should take greater care when taking the readings and increasing the force.
Conclusion
1. To estimate the stress and strain on a material, we plot a stress-strain graph. We do this so that we can then analyze the behaviors of the materials under different stresses and strain more accurately.
2) & 3) Brittle material such as brass do not have a yield, strain hardening and necking regions to their graph. They rupture as soon as the ultimate strength is reached. Ductile materials have yield, strain hardening and necking regions to their graph. They will not rupture when the ultimate strength is reached. They undergo strain hardening and necking before breaking at rupture strength.
4) Young’s Modulus can be found by calculating E=σ/ε. Young’s Modulus is also equivalent to the gradient of the region before reaching the proportional limit in a stress-strain graph. As Young’s Modulus increases, the stiffness of the material increases. We could not determine the Young’s modulus of a material accurately due to errors. The experimental Young’s Modulus for all the materials are:
5) Ductile materials are different from brittle materials as they have yield, strain hardening and necking regions to their graph. They undergo strain hardening and necking before breaking at rupture strength.
As we could achieve four out of the five objectives, the experiment was a success.