ENB110 Lab 1 Tensile Testing 1

QUT, Science and Engineering Faculty

ENB110 Engineering Statics and Materials
Laboratory 1- Tensile Testing

Important Information
This file contains prac handout, laboratory worksheet, CRA and health and safety
information. You MUST prepare yourself before coming to the laboratory:
Wear appropriate clothing such as covered shoe.
Attempt the pre-lab questions (below).
Be aware of the hazards and risks during the prac session and must know the
control measures in-case of accident (information at the end of this file).
On the laboratory worksheet, tick the appropriate boxes and sign before
starting the prac.
This prac will run for 2 hours in the materials lab in O-Block- level 2, Room
217.3. In the first half of the prac session, you will observe a tensile test being carried
out and analyze some tensile test data. In the second half, you will complete the
worksheet and hand-in to your lab demonstrator. Your worksheet will be marked
immediate by your lab demonstrator. Submission after the prac session is concluded is
not acceptable and will not be marked.

Pre-lab questions
Before coming to the prac you are required to answer the following questions in the
worksheet (attached at the end of this document):
1. From your text book obtain the Youngs Modulus, Yield Strength and Ultimate
Tensile Strength of one of the following materials: Aluminum, Brass, or Low
Carbon Steel.
2. Convert 1 N/mm
2
to MPa.
3. What are the units of stress, stain and elastic modulus
Objective of this prac
To become familiar with the tensile testing system and learn how to develop
the load-deformation and stress-strain curves.
To determine important mechanical properties of steel such as Youngs
Modules, Ductility, UTS and Yield Stress from simple sketching of
engineering stress-strain curve.
This will help you develop your own method how to test steel wires for your
project.

1 Introduction
In order to compare and select materials for various applications, one must have
access to the important properties of that material. For example steels are used in
many applications including bridges, machine equipments, automobiles, etc and all
are made from different types of steels. One of the most often used testes performed
to determine a number of important mechanical properties of materials is a tensile
testing method. This method requires first the preparation of test specimen in either
cylindrical or rectangular dog-bone shape. The load applied to the specimen may be
ENB110 Lab 1 Tensile Testing 2
large and may be adjusted according to the type of material tested. For instance, for
soft metals and polymers a lower load is used as compared to other strong materials.
2 Procedure
2.1 Tensile Testing
The engineering tension test is widely used to provide basic design information
on the strength of materials and as an acceptance test for specifications. In the tension
test a specimen is subjected to a continually increasing extension while simultaneous
observations are made of the uniaxial load on the specimen. An engineering stress-
strain curve is constructed from the load-elongation measurements. In the later part of
the session, you will use load and elongation results to draw a stress-strain curve and
calculate some of the most important materials properties parameters from it. In the
first part of the practical session you will see how the load versus elongation curve is
obtained.
The concept behind the Instron Testing machine is very simple. The machine
consists of a fixed crosshead and a moveable crosshead that is driven by a set of
screws (see Figure 1). The specimen is attached between the two crossheads, which
are then driven apart at a constant rate by the leadscrews on either side. These screws
are hidden behind the leadscrew cover on the Instron machine. One end of the
specimen is attached to a device that measures the load on the specimen. This is
called a load cell. The output of the load cell can be plotted against the movement of
the crosshead.



















ENB110 Lab 1 Tensile Testing 3

Figure 2 The extensometer is
attached to the specimen via rubber
bands (In this prac you will not use
extensometer).


Diameter
Gauge
Length
Area

Figure 3 Dimensions for Cylindrical
Tensile Testing Specimen.
Figure 1a Schematic diagram of the testing testing machine.

Figure 1b Photograph of Instron 5569 tensile testing machine.
Where the strain on the specimen is large and the specimen is small compared
with the dimensions of the machine, then the movement of the crosshead will be
approximately the same as the extension of the specimen. Therefore, strain can be
given by dividing the movement of the crosshead by the original specimen length.
However, even such large machines as these are surprisingly flexible and if the load
on the specimen changes dramatically with strain, then the elastic deformation of the
machine becomes important and using crosshead movement to approximate the
extension of the specimen may not be accurate. This is particularly important for
determining the Youngs Modulus and the yield point. In order to get around this
problem, a device called an extensometer (Figure 2) is used.










ENB110 Lab 1 Tensile Testing 4


An extensometer is an electronic device that is clipped onto the gauge length of the
specimen using rubber bands and measures strain directly. It is usually removed once
the yield point has been passed. In this prac you will use crosshead movement to
approximate the extension and you will not use extensometer. Before we start testing,
the dimensions of the specimen (eg. area and gauge length) should be measured. A
gauge length is defined as the length within the reduced region in which the diameter
is uniform and does not change. Because the gauge length has the smallest cross-
section area, bulk of the specimen deformation will appear in this region. The
measurements for a cylindrical specimen are shown in Figure 3.
Metallic specimens which are in a dog-bone shape will be tested in this
experiment. There are four specimens (table below) available in the lab and you will
test at least one of the specimens.

Specimen Type
Aluminum
Brass
Carbon steel
4340
Aluminum alloy
Brass alloy
0.1% Carbon steel - mild steel
0.4% Carbon alloy steel - grade 4340

2.2 Analysis of Tensile Data

After testing of your specimen, the data from the machine can be stored in the
PC as a series of points. The data is then in two columns containing extension and
load. Please note the units used for each as the specimen extension in mm and the
load in N. In the extension results, the compliance of the machine has already been
compensated for.

Stress and strain can be calculated using the following formulas:
Stress=
F
A
o
, and Strain=
l
l
o

You may use this data to sketch the
engineering stress vs strain curve (similar
to Figure 4) and examine various
mechanical properties of the material.

Determining Youngs Modulus from you sketch

Youngs Modulus is the slope of the initial linear elastic part of the graph. This can be
done by choosing two points in the linear portion (
1
,
1
) and (
2
,
2
), and calculate
the slope between them as follows:
E

( )
( )
2 1
2 1


The Youngs Modulus can be expressed in the units of GPa, where 1GPa =1000MPa.

ENB110 Lab 1 Tensile Testing 5
Note that once the graph becomes non-linear, the Youngs modulus cannot be
calculated, so choose your points within the linear region.

Determining 0.2% Proof Stress or Yield Stress
The 0.2% Proof Stress (
ys
) is defined as the stress required to cause 0.2% permanent
plastic deformation in the sample. In order to calculate this value, a line is drawn
parallel to the elastic portion of the graph at an offset corresponding to 0.2%
permanent plastic deformation. Where this line intercepts the stress-strain curve is the
0.2% Proof Stress or Yield Stress.

ys

0.2%
E
=E(-0.002)

Figure 4 Determination of 0.2% Proof stress or Yield Stress.

Determining Ductility of the material
Ductility is the %elongation after fracture. Measure this as the permanent plastic
deformation after fracture.

Determining Ultimate Tensile Stress (UTS)

UTS is the highest engineering stress reached by the specimen. After this point, the
specimen begins to neck and localized deformation occurs. It is naturally the highest
engineering stress reached in the test.

ENB110 Lab 1 Tensile Testing 6
SCIENCE AND ENGINEERING FACULTY
HEALTH AND SAFETY INFORMATION FOR ENB110 PRACS

Risks and Their Controls during ENB110 prac sessions

Activity Hazard Type Risk Control Measures
(Include provision for monitoring)
Indentation
Hardness
Testing using
Rockwell,
Brinell, Vickers
and Universal
Tester Machine
This test involves pressing
an indenter into a test
specimen. The load applied
for making the indentation is
high (e.g. up to 150 kg for
the Rockwell and 3000 kg
for the Brinell). Rockwell
loads need to be changed
when testing the different
types of specimens.
Falling off the weights
when changing the loads
can cause series injury.
The prac can cause a series
of injury if accident
happens due to any
obstacle to the screws,
improper adjustment of the
machine or specimen.
Students should be careful when
changing loads. Indentation should
start when the sample is in place and
no other obstruction is interfering.
Students are required to have a safety
induction card and should wear
appropriate protective items such as
closed shoes or steel capped shoes.

Take the necessary precaution and
use goggles when indentation is
being performed.
Tensile Testing
of Metals using
Instron Machine

A large tensile load (up to 10
kN) is applied to a metal
specimen attached between
two crossheads of an Instron
Machine. The specimen is
then driven apart at a
constant rate by screws on
either side of the Machine
which are hidden in cases on
the Instron Machine. The
specimen will eventually
fracture. The machine can be
controlled by a computer or
manually. Prior to testing a
proper adjustment of the
machine and the specimen is
needed.
The prac can cause a series
of injury if accident
happens due to any
obstacle to the screws,
improper adjustment of the
machine or specimen.

Fractured specimen may
be sharp to cut your finger.
Students should take proper
precautions when mounting samples.
The crossheads and screws should be
free from any obstacles including
students hands. The machine should
start running once proper adjacent
has been done. Students are required
to have a safety induction card and
should wear appropriate protective
items such as closed shoes or steel
capped shoes.

Take the necessary precaution (and if
needed use gloves) when handling
the fractured specimen.




ENB110 Lab 1 Tensile Testing 7
ENB110 Engineering Statics and Materials
Laboratory 1 - Tensile Testing Worksheet
Prac Demonstration in Room O-217

Name
Student Number Group Number
Date of Lab Mark (for tutor only

This worksheet should be handed in during the prac session for marking and should
be collected at the end of the lab demonstration.
I have read the health and safety information and understand the hazards and
risks and control measures.
I have the appropriate clothing (e.g. covered shoes) during the prac session.
I have attempted the pre-lab questions.

Write down your answer for the pre-Lab questions


1. First select one of the three samples (Aluminum, Brass, Steel) for tensile testing :

Sample: ___________________________

2. Tabulate the measured dimensions of your tensile specimen:

.Specimen Dimensions

Your Value Specimen Dimensions

Your Value
Width (mm) Gauge length (mm)
Thickness (mm) Area (mm
2
)

3. Tabulate some representative load and extension data obtained from the test in the
table below.


Load (N)


Extension
(mm)


ENB110 Lab 1 Tensile Testing 8
4. Using the load-extension data obtained from the test and the measured specimen
dimensions, calculate the stress and strain for few representative points:

Stress (MPa)


Strain (%)


5. Sketch the stress-strain curve as explained in section 2.2 and determine the
following material properties:




























Property Symbol

Your Value

Unit
Young's Modulus

GPa
0.2% Proof stress

MPa
Ultimate Tensile
Stress
MPa
Engineering strain at
the point of necking


%
Ductility

%
ENB110 Lab 1 Tensile Testing 9
6. Describe the limitation and advantage of using extensometer to determine the
elastic modulus of the material. What alternative method for measuring E have
you observed?
__________________________________________________________________

__________________________________________________________________

__________________________________________________________________

__________________________________________________________________

__________________________________________________________________

7. What is the difference between the elastic limit and the 0.2% proof stress? For
this material, should we calculate 0.2% proof stress or can we determine the
elastic limit accurately? Why?
____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________
8. How can you measure the mechanical properties of 1 mm diameter steel wire at
your home? What are the expected results as compared to the values obtained
from the dog-bone shaped steel?

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

ENB110 Lab 1 Tensile Testing 10
Engineering Statics & Materials (ENB110) Standard mark:
Student Name: _______________________________ Student number: ________________________________

Criteria
Standard 7 Standard 6 Standard 5 Standard 4 Standard 3 Standard 2/1
Apply
theoretical
and practical
knowledge of
engineering
materials
(50%)








Your worksheet, completed
within the given timelines,
shows that you have
carefully followed the pre-
lab directions to apply your
comprehensive theoretical
and practical knowledge to:
Your worksheet, completed
within the given timelines,
shows that you have carefully
followed the pre-lab directions
to apply your broad theoretical
and practical knowledge to:
Your worksheet, completed
within the given timelines, shows
that you have followed the pre-
lab directions to apply your
theoretical and practical
knowledge to:
Your worksheet, completed or
partly completed within the
given timelines, shows that you
have followed aspects of the
pre-lab directions to apply your
basic theoretical and practical
knowledge to:
Your worksheet,
completed or partly
completed within the
given timelines, shows
that you have followed
aspects of the pre-lab
directions to:
Your worksheet:
accurately measure
dimensions and properties
of the given materials
accurately, for the most part,
measure dimensions and
properties of the given
materials
accurately, for the most part,
measure dimensions and
properties of the given
materials
measure some dimensions
and properties of the given
materials accurately
measure some
dimensions and
properties of the
given materials
was incomplete
within the given
timelines
correctly employ all
commonly used symbols as
specified by the tasks,
define concepts, list and/or
describe behaviour of
materials and their
applications, determine
suitability of particular
testing techniques
correctly, for the most part,
employ the commonly used
symbols as specified by the
tasks, define concepts, list
and/or describe behaviour of
materials and their
applications, determine
suitability of particular
testing techniques
correctly, for the most part,
employ the commonly used
symbols as specified by the
tasks, define most of the
concepts, list and/or describe
behaviour of materials and their
applications, comment on the
suitability of particular testing
techniques
partly employ commonly
used symbols as specified by
the tasks, list and/or describe
behaviour of materials and
their applications, explain
how the testing equipment
works rather than determine
suitability
employ few symbols
and/or units as
specified by the tasks
and list some of the
applications of the
materials
you havent followed
the practical
guidelines and
directions to
complete your
worksheet
Solve simple
numerical
problems ;
interpret and
analyse
gathered data
and
information
(50%)





Your worksheet, completed
within the given timelines,
shows that you used the
gathered data and/or derived
graph to:
Your worksheet, completed
within the given timelines,
shows that you used the
gathered data and/or derived
graph to:
Your worksheet, completed
within the given timelines, shows
that you used the gathered data
and/or derived graph to:
Your worksheet, completed or
partly completed within the
given timelines, shows that you
used the gathered data and/or
derived graph to:
Your worksheet
completed within the
given timelines, shows
that you used the
gathered data and/or
derived graph to:
Your worksheet partly
completed within the
given timelines
correctly calculate all the
expected values for the
material properties

correctly calculate most of
the expected values for these
material properties

correctly calculate most of the
expected values for these
material properties

perform partly correct
calculations of the expected
values for these material
properties

perform a few
calculations and the
resulting values are
incorrect for these
material properties
shows that you are
unable to use the
gathered data
interpret and analyse the
data to concisely and
correctly explain the
behaviour of the given
materials under different
testing techniques
interpret and analyse the data to
concisely explain the behaviour
of the given materials under
different testing techniques,
and these explanations are
predominantly correct
interpret and analyse the data to
explain the behaviour of the
given materials under different
testing techniques, and some of
these explanations are correct
interpret and analyse some of
the data to describe the
behaviour of the given
materials under different
testing techniques
state some
observations about
the behaviour of the
given materials under
different testing
techniques
desired properties
werent performed