TABLE OF CONTENT

Content

Page

1.0 Project Background

2.0 Literature Review

3.0 Methodology

4.0 Result and Discussion

10

5.0 Conclusion

14

7.0 References

15

8.0 Appendix

16

1.0 PROJECT BACKGROUND

1.1. Background of Sample (Refer to the Figure 1.1.1)

Sample Characteristic:

Rectangular shape
Cloudy color
Not easily broken

Sample Dimensions:

Length: 86mm
Width: 12mm
Thickness: 3mm

Figure 1.1.1

1.2. Problem Statement

Nowadays, materials are very widely used and even since the ancient times. When in service,
materials are subjected to loads, forces, torques and many more. However, sometimes the usage
of a material does not last longer due to the amount of usage exceed the amount that has been
specified for the material. Therefore, before using a material, the properties such as the
mechanical properties, chemical properties and other properties should be known for the
maximum usage of the material. For this project, our group chose to do flexural and hardness test
in order to determine the material properties, which is strength and durability. This test was
chosen based of the design of the sample. From those tests, we will get the mechanical properties
of the sample given.
1.3. Objectives
The objectives of this project are as follows:
1) To determine two mechanical properties of the given specimen, strength and durability.

1.4. Scopes
The scopes of work that involve throughout this project are:
2

1) Analyze the mechanical properties of the sample using two methods that has been given.
a) Flexural test (ASTM D790)
b) Hardness test (ASTM D785)

2.0 LITERATURE REVIEW

2.1 Polymer
Polymers are constructed from relatively small molecular fragments known as monomers that are
joined together; refer to Figure 2.1.1 in appendix. Synthetic polymers which include the large
group known as plastics came into the prominence in the early twentieth century. Chemist able to
construct them to yield desired set of properties (strength, stiffness, density, heat resistance,
electrical conductivity) has greatly expended the many roles they play in the modern industrial
economy (Stephan Lower, 2009).
Polymer can be classified in many different types and name, which can be determined by using
mechanical test. A mechanical test shows whether a material or part is suitable for its intended
mechanical applications by measuring elasticity, tensile strength, elongation, hardness, fracture
toughness, impact resistance, stress rupture, and fatigue limit (Mechanical Testing, 2013).
2.2 Flexural Test
The flexure test method used to measure the flexural strength of the object and behavior of
material subjected to simple beam loading. Flexural strength defines as the maximum stress of
the outermost fiber. The flexural strength represents the highest stress experienced within the
material at its moment of rupture. Based on Dr. Donald F. Adam (2013), flexural strength and
stiffness are not basic material properties. They are the combined effects of a materials basic
tensile, compressive and shear properties.
In flexural stress there are two type of test which is three points bending test and four points
bending test (refer to Figure 2.2.1 and Figure 2.2.2 in appendix). Materials that do not fail by
maximum strain allowed under these test method (3 point bend) may be more suited to a 4 point
bending test. If we consider the Weibull statistic, it is to be expected that mechanical strength
measured through 4 point bend is lower than one measured through 3 point bending (J.A.
3

Rodrigues, 2014). For our project we were given a polymer, which considered ductile. Based on
this assumption and the dimension of the specimen tensile test according to ASTM standards
D790 will be conducted to further confirm the approximation made earlier. These test method
cover the determination of flexural properties reinforced and unreinforced plastic including high
modulus composite and electrical insulating material in the form of rectangular bars molded
directly or cut from sheets, plates or molded shapes (ASTM International D790, 2003).
Before conducting the experiment, the value of rate of crosshead motion need to known:
R=

Where:

Z L2
6d

Equation 2.1

R = rate of crosshead motion

L = support span
d = depth of beam
Z = 0.01

The formula that need to used to find the value of flexural strength:
FS=

3 FL
2
2bd

Where:

Equation 2.2

F = fracture load
L = distance between support
points
b = width of specimen
d = height of the specimen

2.3 Hardness Test

Hardness is a resistance of a material to permanent indentation. It is important to recognize that
hardness is an empirical test and therefore hardness is not a material property. Hardness is,
4

however used extensively to characterize materials and to determine if they are suitable for their
intended use. All of the hardness tests stated in this literature review involve the use of a
specifically shaped indenter (refer to Table 2.3.1 in appendix), significantly harder than the test
sample that is pressed into the surface of the sample using a specific force. Either the depth or
size of the indent is measured to determine a hardness value. There are five major hardness
scales, Brinell HB, Knoop HK, Rockwell HR, Shore HS and Vickers HV (Tinius Olsen,
2008).
The hardness testing of plastics is most commonly measured by the Rockwell hardness test or
Shore (Durometer) hardness test. Both methods measure the resistance of the plastic toward
indentation. Both scales provide an empirical hardness value that does not correlate to other
properties or fundamental characteristics. Rockwell hardness is generally chosen for 'harder'
plastics such as nylon, polycarbonate, polystyrene, and acetyl where the resiliency or creep of the
polymer is less likely to affect the results. So for our specimen, we choose the Rockwell
Hardness test due to its ductility and it is easiest test to conduct.
The Rockwell Hardness test is a hardness measurement based on the net increase in depth of
impression as a load is applied (refer to Figure 2.3.1 in appendix). Hardness numbers have no
units and are commonly given in the R, L, M, E and K scales. The higher the number in each of
the scales means the harder the material. The results obtained from this test are a useful measure
of relative resistance to indentation of various grades of plastics. However, the Rockwell
hardness test does not serve well as a predictor of other properties such as strength or resistance
to scratches, abrasion, or wear, and should not be used alone for product design specifications.

3.0 METHODOLOGY
3.1 Flexural Test.
3.1.1 Tools and Equipment

3.1.2

Universal Testing Machine (UTM), (refer to Figure 3.1.1.1 in appendix)

Micrometer, (refer to Figure, 3.1.1.2 in appendix)
Test specimen. (refer to 3.1.1.3 in appendix)
Procedure

1) Measure the dimension of the specimen by using the micrometer provided

2) Record the dimension of the specimen in the table provided.
3) The width and depth of the specimen is measured to the nearest 0.03 mm at the centre of
the support span.
4) The specimen is placed on the span of the machine according to the measurement before.
5) The test begins after the machine is initialized. The hydraulic ramp slowly push the
specimen. 12.8mm/min hydraulic ramp speed is used to pushed the specimen. The
machine recorded the load and corresponding displacement into a data file created at the
beginning of the initialization stage.
6) The test is continued untill test specimen has reached maximum strain in outer surface
which is 0.05 mm/mm.
7) By using another specimen, repeat step 1 until 6. Analyzed load-strain graph and data
recorded from computer. Then calculate the flexural strength using Equation 3.2.
3.2 Rockwell Hardness Test
3.2.1 Tools and Equipment

Rockwell Hardness Testing Machine (refer to Figure 3.2.1.1 in appendix)

Indenters (1/2 inch steel ball)
Specimen support and the Sample Polymer

3.2.2 Procedure
1) Clean the specimen and the indenter from dirt or other foreign materials.
2) Divide the specimen into 5 parts by using normal ruler to make sure the indenter of the
Rockwell hardness machine properly placed within the parts (refer to Figure 3.2.2.1 in
appendix).
3) The sample was place on the anvil below the indenter and 10kg minor load is applied on
the specimen for a few seconds. The minor load functioned to make the zero setting of
the machine.
6

4) The major load 60kg was then applied to the first section of the sample for about 15
seconds, in order to take the first reading.
5) The number shown on the digital gauge was recorded.
6) Repeat step 3 until 5 for the remaining section on the sample. Zeroing the sample is
required only once. Then calculate the Rockwell hardness number using suitable formula:
Rockwell Hardness number = 150 (indention under load)

3.3 Project Activities

Table 3.3.1: Task Division
Group Members
Group leader

Tasks and Division of Report

- Performed Flexural Test, Hardness Test

Muhammad Nurshafiq Bin Ramli

- Literature Review for Flexural Test

- Result for Hardness Test
- Performed Flexural Test, Hardness Test

Muhammad Shamil Bin Zulkipli

7

- Methodology for Flexural Test

Equation
3.1

- Result for Flexural Test

- Performed Flexural Test, Hardness Test
Muhammad Syahmie Bin Che

- Literature Review for Hardness Test

Suliman

- Discussion for Hardness Test

- Performed Flexural Test, Hardness Test

Nabil Hariz Bin Mohd Ariff

- Methodology for Hardness Test

- Discussion for Flexural Test
- Performed Flexural Test, Hardness Test

Ameer Sholehuddin Bin Yahya

- Project Background for Specimen

- Conclusion of the report

Table 3.3.2: Meeting Schedule

Time
Week 7
Week 9
Week 12

Content
Task division for progress report
Compilationof progress report
Discussion for progress VIVA

Compilation for final report

Discussion for final VIVA

3.4 Gantt Chart

Table 3.4.1: Gantt chart

Activity
Lab Briefing
Group Division
Sample Collection
Sample Research

Week

Week

Week

Week

Week

Week

Week

Week

Week

Week

Week

10

11

12

Conduct
Experiment

Dividing Task for

Progress VIVA
Group

Progress

VIVA
Result and
Discussion
Report Correction
Submission

Final

Report
Final VIVA

Key Milestone
4.0 RESULT AND DISCUSSION
4.1 Result of Flexural Test
Table 4.1.1: Reading from flexural test
Test no.

Span

Width

Max. Load,

Max. Load,

Strain

Elastic modulus,

1
2

(mm)
48
48

(mm)
12.33
12.33

(N)
61
61

(MPa)
35.503
35.597

(%)
5.115
5.174

(MPa)
929.588
885.820

Table 4.1.1 shows the tablature of the readings obtained from the flexural test conducted, and
Figure 4.1.1 and Figure 4.1.2 plots the relationship of maximum load vs. percentage of strain.

Compression result test 1

40
36
32
28
24

Max. load, MPa

20
16
12
8
4
0

1.5

4.5

7.5

10.5

12

13.5

15

Strain, %

Figure 4.1.1: Compression Result Test 1

Compression result test 2

40
36
32
28
24

Max. load, MPa

20
16
12
8
4
0

1.5

4.5

7.5

Strain, %

Figure 4.1.2: Compression Result Test 2

Calculation of flexural strength using Equation 2.2:

10

F=61 N
L=47 mm

b=12mm

10.5

12

13.5

15

3 FL
2
2bd
3(61)(0.047)

2
2(0.012)(0.003)

Flexural streng h t , FS=

39.8 MPa

We found that flexural strength of our sample is G = 39.8MPa

4.2 Result of Rockwell Hardness Test

Table 4.2.1: Value of indention at different point.
Indention point
A
B
C
D
E

11

Value of indention
91.0
89.7
89.3
81.4
81.4

The Hardness Value at different Point

92
90
88
86
84
82
80
78
76
A

Figure 4.2.1: Hardness Value

Based on the result, the average value of the indention is:

e=

91.0+89.7+ 89.3+81.4+ 81.4

5

= 85.56
Therefore by using Equation 3.1, the value of Rockwell Hardness number is 64.44.

4.3 Discussion
4.3.1 Flexural Test
Graph of stress as a function of strain can be constructed from data obtained in flexural test
where load is applied to a material, and continuous measurements of stress and strain are made
simultaneously. The applied load is converted to applied stress, and the resulting elongation is
converted to strain. The two sets of graph plotted as the result obtain in the table.
The result of the experiment shows maximum load, percentage of strain and elastic modulus of
each respective specimens. As for the first specimen, the modulus of elasticity obtained is
12

929.588MPa while the second specimen is 885.82MPa. The other highlighted mechanical
property is flexural strength. By applying flexural strength formula the flexural strength is
39.8MPa for both specimens.
From the graph, the modulus elasticity is measured at the linear region of the curve. At the point
where the curve no longer shows linearity, so some permanent dimensional deformation will
occur. This point is called the elastic or proportional limit. From this point, the specimen reacts
plastically to any increase in load or stress. The material will not return to its original, unstressed condition, size or shape, if the load is removed.
During this experiment, there are some errors caused the result to become inaccurate. One of
them is human error. When reading the calipers, eyes of observer are not perpendicular to the
scale and causing parallax error. The other error that might be occurring is positioning sample
wrongly at the machine during experiment.
Modifications that can be done are by taking the measurement several times and take the average
of the readings. Besides, ensure the eyes of the observer are perpendicular to the calipers scale
while taking a reading. Next we need to position the sample properly by following exactly the
procedure and guidance from the lab technician.

4.3.2 Rockwell Hardness Test

Rockwell B hardness test have been utilized to conduct the test following the ASTM standard for
hardness test. The indenter used was a inch diameter ball, the major and minor load used are
both 60kg and 10 kg. The value of indention is taken from different point at different distance.
The hardness value of 64.44HRR is obtained from substituting the average value of indention
into Equation 3.3, which is below 100 HRR. So our specimen is on the right range for polymer.
During the experiment some error can be found that caused the result to be inaccurate. As for the
difference of the hardness number which due to calibration error when conducting the
13

experiment. The machine itself was not fully calibrate due to poor condition, as been told by the
lab assistant. Thus, it results to different hardness value at the different points. The thickness of
the specimen is too thin from the standard value for the experiment which is 6mm. So the result
is a bit different and also inaccurate.
The indenter and the specimen should be clean thoroughly before the experiment started because
it will affect the value of the hardness, as the machine is sensitive. The machine work as the
indenter is forced by load beyond the depth resulting from the previously applied minor load. So
if there was a layer of dirt existed on the indenter or the specimen, the result will be inaccurate.

5.0 CONCLUSION

The value for the first mechanical properties, strength which is the value for flexural strength is
39.8Mpa. The value for the second mechanical properties, durability which is the value of
Rockwell hardness number is 64.44HRR.

6.0 REFERENCES
ASTM International, Standard Test Methods For Flexural Properties of Unreinforced and
Reinforced Plastics and Electrical Insulating Materials, MC Master University, D790 03,
2003.
ASTM International, Standard Test Methods For Rockwell Hardness Of Plastics and Electrical
Insulating Materials, MC Master University, D785 03, 2003.

14

F. Donald. (March 2013). Flexural Testing of Composite Materials. Retrieved March 7, 2015,
10.00pm, from CompositeWorld.com: http://www.compositesworld.com/articles/flexural-testingof-composite-materials(2)
J. A. Rodrigues. (2014). 3 Point and 4 Point Bending Stress Test. Retrieved March 8, 2015,
12.30am,

from

http://www.researchgate.net/post/Why_do_we_have_both_3-point_and_4-

point_bending-strength_tests
L. Stephan. (September 2009). Polymer and Plastic: An Introduction. Retrieved March 8, 2015,
1.00am, from StatCounter.com: http://www.chem1.com/acad/webtext/states/polymers.html
Mechanical Testing. (2013). Retrieved March 8, 2015, 8.00am, from Element Materials
Technology: http://www.element.com/services-index/services/mechanicaltesting
Tinius Olsen. (2008). Type of Test. Retrieved April 1, 2015, 11.00pm, from Tinius Olsen.com:
http://www.tiniusolsen.com/types-of-tests/hardness-test.html

7.1 APPENDIX

Figure
2.1.1: Molecular structure of
15
polymer

Figure 2.2.1: 3 point bending test

Figure 2.2.2: 4 point bending test

Table 2.3.1: Types of Hardness
Scale

Figure 2.3.1: Hardtip

Figure 3.1.1.1: Universal Testing Machine

16

Figure 3.1.1.2: 150mm Digital Vernier

Figure 3.1.1.3: Polymer specimen

Figure 3.2.1.1 Rockwell Hardness Test

Machine

Figure 3.2.2.1: Points of Indention of loads

17