TMM SS 2013

KL_TMM_SS13 18.10.2013 Page 1 of 4

Prof. Dr.-Ing. P. J. Mauk 21.08.2013
Ch. Overhagen, M.Sc.
Institute for Metallurgy and Metal Forming

Examination: Testing of Metallic Materials / SS 2013

Advice: Use a new page for every problem!
Place your name and matricle number on top of page 2 !

Total: 118 points ; 4.0 = sufficient: 47 min. points ; 1.0 = excellent: 106 min. points

Engineering Strain :
ENG
c True Strain :
TRUE
c
Engineering Stress :
ENG
o True Stress :
TRUE
o
ENG TRUE
0
ENG TRUE
0
F F
A A
dl dl
d d
l l
o = o =
c = c =


1. Problem (25 Points):
At room temperature, a frictionless upsetting test is conducted on a metallic sample
of initial diameter d0 = 25 mm and initial height h0 = 50 mm. At a force of F = 650 kN,
a machine displacement of s = 17.3 mm is measured. The testing machine has an
elastic rigidity modulus of CM = 630 kN/mm.
a) Determine the engineering stress o for this case !
b) Calculate the plastic deformation of the sample and the elastic deformation of
the machine (elastic sample deformation can be neglected).
c) Calculate the diameter of the sample at that time.
d) Determine the engineering strain ch.
e) Calculate the true strain and true stress (flow stress).


2. Problem (12 Points):
A fine grain construction steel with a mean grain size of 17 m has a yield stress of
Rp0,2 = 350 MPa. At a mean grain size of 12 m the yield stress will be 370 MPa.

a) Determine from these data the constants of the Hall-Petch-equation

1
2
p0,2 F i y
R k d

= o = o +


b) What yield stress can be expected at a grain size of 8 m based on the data
given above ?

c) Describe the influence of grain size on yield stress by means of the Hall-Patch-
equation!





TMM SS 2013

KL_TMM_SS13 18.10.2013 Page 2 of 4
Name:

Matricle Number:


3. Problem (15 Points):
The plot below shows the homogeneous elongation region of a stress-strain curve of
a tensile test on a prestrained rod (
0
0.35 =
) made from construction steel.
(Small interval on strain axis = 0.025 %, Small interval on stress axis = 20 N/mm)

Solve the following tasks graphically:

a) Approximate Youngs Modulus E for this material from the measured data.
b) Find the engineering yield stress Rp0.2 at a plastic strain of 0.2 %.
c) Find the engineering yield stress Rp0.05 at a plastic strain of 0.05 %.





4. Problem (12 Points):
Describe the following sheet metal tests in your own words:

a) Erichsen Test
b) Up-and-down bending test
c) Nakazima Test
d) Swift Cupping Test
What data is found in each of those test procedures ?


TMM SS 2013

KL_TMM_SS13 18.10.2013 Page 3 of 4
5. Problem: (20 Points)
A tensile test on a sample with diameter d0 = 15 mm and a measuring length of
L0 = 82.5 mm results in a maximum force of Fmax = 112 kN. The elongation at
maximum force is a change in length of l = 11.5 mm. The specimen length after
fracture is 99.0 mm, the smallest necked diameter of the specimen is 7.3 mm.
The force at fracture is 45 kN.

a) Find the engineering stress and strain and the true stress and strain at
maximum force.

b) Find the local true stress and true strain at the smallest necked diameter at
fracture.

c) Calculate the fracture strain in % and the reduction of area in %.

d) In the elastic region at a force of 12 kN, a change in length of 0.008 mm is
measured with an extensometer, having an initial gauge length of l0,extensometer = 25
mm. Calculate Youngs modulus of this material!

e) For the case according to d) a change in diameter of the sample of
-0.0015 mm is measured. Determine Poissons Ratio for this material.

6. Problem (12 Points):
In a part which is made from a steel material with 85
IC
K MPa m = , a Griffith-Crack
( 1
I
Y = ) is discovered at mode 1 loading. Calculate the critical stress which leads to
unstable crack growth for the following crack lengths:

a) a = 5 mm
b) a = 10 mm
c) a = 15 mm
d) The part is loaded at a nominal stress of S = 185 N/mm. Calculate the critical
crack length after which unstable crack growth will be encountered.


7. Problem (12 Points):
A flat tensile specimen with initial dimensions thickness s0 = 1.5 mm, measuring
length L0 = 95 mm and width w0 = 17 mm is being deformed in a testing machine for
a time of 30 seconds with a tool velocity of v = 0.5 mm/s in the homogeneous strain
region. After the deformation, the width was measured to be w1 = 16.5 mm.

a) Calculate the longitudinal strain
l
and the measuring length of the deformed
sample.
b) Calculate the r-value.
c) Calculate the final thickness s1.
d) At an engineering strain of c1 = 0.12, a force of F1 = 13.7 kN is measured. At
an engineering strain of c2 = 0.15 the force is measured to be F2 = 14.0 kN.
Calculate the n-value !



TMM SS 2013

KL_TMM_SS13 18.10.2013 Page 4 of 4
8. Problem (10 Points):
A part is loaded swelling at a nominal stress of
2
N
S 75
mm
A = . The initial crack length
is a0 = 1.25 mm. The following data are given: m = 4 and the geometry factor
Y = 2.5 = const.
The Paris equation is valid in the form
REF m
REF
da da K
dn dn K
A | | | |
=
| |
A
\ . \ .
.
The reference quantities shall be taken as
| |
REF
3
da
1 10 mm
dn

| |
=
|
\ .
and
0
REF
a a
K K
=
A = A .

Calculate the number of load cycles, until a critical crack length of ac = 5.14 mm is
reached !