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List of Experiments:
1. To study the Brinell hardness testing machine & perform the Brinell hardness test.
2. To study the Rockwell hardness testing machine & perform the Rockwell hardness test.
3. To study the Vickers hardness testing machine & perform the Vickers hardness test.
4. To study the Erichsen sheet metal testing machine & perform the Erichsen sheet metal test.
5. To study the Impact testing machine and perform the Impact tests (Izod & Charpy).
6. To study the Universal testing machine and perform the tensile test.
9. To study the torsion testing machine and perform the torsion test.
10. To draw shear Force, Bending Moment Diagrams for a simply Supported Beam under Point and Distributed Loads.
11. To determine Mechanical Advantage and Efficiency of Single and Double Purchase Winch Crab.
12. To determine Mechanical Advantage and Efficiency of Worm and Worm Gear of Single, Double and Triple start.
13. To determine Mechanical Advantage, Efficiency of Simple and Compound Screw Jack.
Note:
2. At least eight experiments should be performed from the above list. Remaining two experiments may either be
performed from the above list or designed & set by the concerned institute as per the scope of the syllabus.
EXPERIMENT No. 1
Aim:
To determine the M.A.,V and efficiency of a square thread screw jack and plot a graph between
W and P and W and efficiency.
Apparatus used:
1. Screw Jack Apparatus
2. Slotted & Conical Weights
3. Nylon String
4. Meter Rod & Pan
Theory:
This machine is used for lifting heavy load with the application of a smaller effort. It may have
different shapes but the principle is same I, e, it works on the principle of a screw. The screw
head carries the load w. the nut is fixed and the screw is rotated by means of a lever. The effort
p is applied at the screw is rotated by means of a lever. The effort p is applied at the end of the
lever. Please see fig.
Now if the screw head revolves through n number of revolutions, the load w placed on the
screw head will move by a distance p x n, where p is the pitch of the screw thread. The effort p
will move a distance n x 2 R, where 2r is the circumference of the screw head over which P is
coming.
There fore
V = Distance moved by the effort P
Distance moved by the load W
= n x 2 R = 2R
nxp p
Procedure:
1. Wrap on string round the circumference of the screw head and take it over a small pulley .
Effort p1 is tied to the free end of this string.
2. Wrap another string around the circumference of the screw head in the same direction in
which the above string is wounded and take it over the other small pulley.
3. Place a load w on the screw head.
4. Suspend p1 and p2 to the free ends of both the strings coming over the two small pulleys.
This load p1 and p2 should be increased gradually suitable to give a just upward motion to the
load w placed on the screw head.
5. Note down w and p to determine the M.A. i.e w/p. in this case p1+p2 will be the value of p.
6. p1 and p2 should be noted down carefully.
7. Take in this way about 10 reading by increasing w and finding out the corresponding value
of P(p1+p2).
8. Measure the circumference of the screw head.
9. Measure the pitch i.e. the distance between the two consecutive threads.
Observations
1. Circumference of the screw Head = 2R=
2. Pitch =
S. No. Load Lifted Effort P1 Effort P2 Total M.A. = Velocity Percentage
Upward W Effort W/P Ratio V Efficiency
P1+P2
1.
2.
3.
4.
5.
EXPERIMENT No. 2
Aim: To study the UTM and perform the tensile test.
Apparatus: A UTM, mild steel specimen, vernier caliper/micrometer, dial gauge & graph paper.
Theory:
Various m/c and structure components are subjected to tensile loading in numerous application. For safe
design of these components, there ultimate tensile strength and ductility one to be determine before actual use.
Tensile test can be conducted on UTM. A material when subjected to a tensile load resists the applied load by
developing internal resisting force. These resistances come due to atomic bonding between atoms of the material.
The resisting force for unit normal cross-section area is known as stress. The value of stress in material goes on
increasing with an increase in applied tensile load, but it has a certain maximum (finite) limit too. The minimum
stress, at which a material fails, is called ultimate tensile strength. The end of elastic limit is indicated by the yield
point (load). This can be seen during experiment as explained later in procedure with increase in loading beyond
elastic limit original cross-section area (Ao) goes on decreasing and finally reduces to its minimum value when the
specimen breaks.
Procedure:
1. Measure the diameter of the specimen at three different sections. Calculate the original
diameter by taking average of three readings. The minimum overall length of the specimen shall
be 20 times diameter plus 200 mm.
2. Mark the points over the grip length, with the punch such that the distance between two
consecutive points is half the gauge length.
3. Select a suitable loading range depending on the diameter of specimen. Start the UTM
and adjust the dead weight of movable heads and then set the load pointer to zero.
4. Fix the specimen bar between the grips of top and middle cross heads of loading frame.
5. Attach the extensometer on the bar at the central portion of the bar. The distance
between upper and lower pivots of extensometer shall be equal to gauge length.
6. Switch on the machine and open the control valve so that the load is increased gradually
and at the required rate.
7. Record the load at suitable interval from the digital display unit or the load dial.
8. Corresponding to loads, note the readings of extensometer.
9. For initial few observations, load and extension are in pace with each other. Record the
yield point load by observing the hesitation of load pointer. The extension readings are faster at
this moment.
10. Remove the extensometer; hence measure extension by divider or suitable scale
11. Record the maximum load. Observe the decrease in load and neck formation on the
specimen.
12. Record the load at fracture and put off the machine.
13. Remove the specimen. Observe the cup and cone formation at the fracture point. Rejoin
the two pieces, measure the final gauge length and the reduced diameter.
Observations:
Calculations:
EXPERIMENT No. 3
Aim: To Perform compression test on UTM.
Apparatus: A UTM or A compression testing m/c, cylindrical or cube shaped specimen of cast iron,
Alumunium or mild steel, vernier caliper, liner scale, dial gauge (or compressometer).
Theory:
Several m/c and structure components such as columns and struts are subjected to compressive load in applications.
These components are made of high compressive strength materials. Not all the materials are strong in compression.
Several materials, which are good in tension, are poor in compression. Contrary to this, many materials poor in
tension but very strong in compression. Cast iron is one such example. That is why determine of ultimate
compressive strength is essential before using a material. This strength is determined by conduct of a compression
test. Compression test is just opposite in nature to tensile test. Nature of deformation and fracture is quite different
from that in tensile test. Compressive load tends to squeeze the specimen. Brittle materials are generally weak in
tension but strong in compression. Hence this test is normally performed on cast iron, cement concrete etc. But
ductile materials like aluminium and mild steel which are strong in tension, are also tested in compression.
Procedure:
1. Dimension of test piece is measured at three different places along its height/length to determine the
average cross-section area.
2. Ends of the specimen should be plane for that the ends are tested on a bearing plate.
3. The specimen is placed centrally between the two compressions plates, such that the centre of moving
head is vertically above the centre of specimen.
4. Load is applied on the specimen by moving the movable head.
5. The load and corresponding contraction are measured at different intervals. The load interval may be as
500 kg.
6. Load is applied until the specimen fails.
Observation:
1. Initial length or height of specimen h = ------mm.
2. Initial diameter of specimen do = -------------mm.
S.No. Applied load (P) in Newton Recorded change in length (mm)
Calculations:
EXPERIMENT No. 4
Aim: To perform the bending test on UTM.
Apparatus used: UTM or Beam apparatus, Bending fixture, vernier caliper, meter rod, test piece &dial gauge.
Theory: Bending test is perform on beam by using the three point loading system. The bending fixture is supported
on the platform of hydraulic cylinder of the UTM. The loading is held in the middle cross head. At a particular load
the deflection at the center of the beam is determined by using a dial gauge. The deflection at the beam center is
given by: = WL3 / 48EI
Procedure:
1. Measure the length, width and thickness of test piece, by vernier caliper.
2. Place the bending fixture on the lower cross head of the testing m/c.
3. Place the test piece on the rollers of the bending fixture.
4. By loading the dial gauge in a stand, make its spindle knob the test piece.
5. Start the m/c and note down the load and dial gauge readings.
6. Plot the graph between load and deflection.
Observations:
1. Least count of vernier caliper = -----
2. Length of beam (L) = --------
3. Width of beam (b) = ------
4. Thickness of beam (t) = ------
S.No. Load W in Newton Deflection in mm. Youngs Modulus E N/mm2
N/mm2
Calculations:
I = bt3 / 12
= WL3 / 48EI
EXPERIMENT No. 5
Aim: To perform the shear test on UTM.
Theory: A type of force which causes or tends to cause two contiguous parts of the body to slide relative to each
other in a direction parallel to their plane of contact is called the shear force. The stress required to produce fracture
in the plane of cross-section, acted on by the shear force is called shear strength.
Procedure:
The method for determining the shear strength consists of subjecting a suitable length of steel specimen in full cross-
section to double shear, using a suitable test rig, in a testing m/c under a compressive load or tensile pull and
recording the maximum load F to fracture.
Observation:
Applied compressive force (F) = ---------kgf.
Diameter of specimen = ---------mm.
Calculations:
The shear strength shall be calculated from the following formulae :
s = (F/2) / (d2/4) = 2F / d2
EXPERIMENT No. 6
Aim: To determined impact strength of steel.
Apparatus used: Impact testing machine, steel specimen 75 mm X 10mm X 10mm
Theory: An impact test signifies toughness of material that is ability of material to absorb energy during plastic
deformation. Static tension tests of unnotched specimens do not always reveal the susceptibility of a metal to brittle
fracture. This important factor is determined by impact test. Toughness takes into account both the strength and
ductility of the material. Several engineering materials have to withstand impact or suddenly applied loads while in
service. Impact strengths are generally lower as compared to strengths achieved under slowly applied loads. Of all
types of impact tests, the notch bar tests are most extensively used. Therefore, the impact test measures the energy
necessary to fracture a standard notch bar by applying an impulse load. The test measures the notch toughness of
material under shock loading. Values obtained from these tests are not of much utility to design problems directly
and are highly arbitrary. Still it is important to note that it provides a good way of comparing toughness of various
materials or toughness of the same material under different condition. This test can also be used to assess the ductile
brittle transition temperature of the material occurring due to lowering of temperature.
Procedure: Izod test
1. With the striking hammer (pendulum) in safe test position, firmly hold the steel specimen in impact
testing machines vice in such a way that the notch face the hammer and is half inside and half above
the top surface of the vice.
2. Bring the striking hammer to its top most striking position unless it is already there, and lock it at that
position.
3. Bring indicator of the machine to zero, or follow the instructions of the operating manual supplied
with the machine.
4. Release the hammer. It will fall due to gravity and break the specimen through its momentum, The
total energy is not absorbed by the specimen. Then it continues to swing. At its topmost height after
breaking the specimen, the indicator stops moving, While the pendulum falls back. Note the indicator
at that topmost final position.
5. Again bring back the hammer to its idle position and back
EXPERIMENT No. 7
Aim: To determined impact strength of steel.
Theory: An impact test signifies toughness of material that is ability of material to absorb energy during plastic
deformation. Static tension tests of unnotched specimens do not always reveal the susceptibility of a metal to brittle
fracture. This important factor is determined by impact test. Toughness takes into account both the strength and
ductility of the material. Several engineering materials have to withstand impact or suddenly applied loads while in
service. Impact strengths are generally lower as compared to strengths achieved under slowly applied loads. Of all
types of impact tests, the notch bar tests are most extensively used. Therefore, the impact test measures the energy
necessary to fracture a standard notch bar by applying an impulse load. The test measures the notch toughness of
material under shock loading. Values obtained from these tests are not of much utility to design problems directly
and are highly arbitrary. Still it is important to note that it provides a good way of comparing toughness of various
materials or toughness of the same material under different condition. This test can also be used to assess the ductile
brittle transition temperature of the material occurring due to lowering of temperature.
Procedure: Charpy Test
1. With the striking hammer (pendulum) in safe test position, firmly hold the steel specimen in impact testing
machines vice in such a way that the notch face s the hammer and is half insider and half above the top surface of
the vice.
2. Bring the striking hammer to its top most striking position unless it is already there, and lock it at that position.
3. Bring indicator of the machine to zero, or follow the instructions of the operating manual supplied with the
machine.
4. Release the hammer. It will fall due to gravity and break the specimen through its momentum, The total
energy is not absorbed by the specimen. Then it continues to swing. At its topmost height after breaking the
specimen, the indicator stops moving, while the pendulum falls back. Note the indicator at that topmost final
position.
5. The specimen is placed on supports or anvil so that the blow of hammer is opposite to the notch.
EXPERIMENT No. 8
Aim: To determine Mechanical Advantage, V.R. and Efficiency of worm and worm gear of single,
double and triple start.
Apparatus: Worm and worm gear of single, double and triple start and weights.
Theory: As the pulley of the worm moves through n revolutions, n teeth of the wheel pass
completely through the worm. If there are N teeth in the worm wheel, then N revolutions will
have to be given to the pulley of the worm to rotate completely the worm wheel. So that if the
effort applied at the pulley of the worm moves through N revolution the load is raised up by the
a distance equal to the length of the circumference of the pulley of the worm wheel.
So that velocity ratio is
N x circumference of pulley of worm
Circumference of pulley of worm wheel
Procedure:
1. Wrap the string round the pulley of the worm the free end of which is to be tied to the effort.
2. Wrap another string to carry the load round the pulley the worm wheel in such a manner
that as the effort is applied the load is lifted up.
3. Suspend a small weight (w) through the free end of the second string and suspend another
weight (p) through the free end of the first string which should just move the load upward.
4. Note w and P, so that mechanical advantage is given by W/ P
5. Increase the load (w) gradually and increase the effort (p) correspondingly and take
in this way about seven readings.
6. Measure the circumference of the pulley of the worm and also that of the worm wheel.
7. The percentage efficiency is given by W x 100 /PV
8. Plot a graph between w and p.
9. The same procedure can be followed for single, double and triple start worm and worm
wheel.
Observations :
1. Circumference of pulley of the worm (2R 1) = _________ cm.
2. Circumference of pulley of the worm wheel (2R 2) =_________ cm.
3. No of teeth in the worm wheel (N)=
4. Velocity ratio for single start= (N x 2R 1)/((2R2)*1)
5. Velocity ratio for double start= (N x 2R 1)/((2R2)*2)
6. Velocity ratio for triple start= (N x 2R1)/((2R2)*3)
Conclusion: Hence the efficiency of single, double and triple worm and worm wheel is completed.
EXPERIMENT No. 9
Aim: To determine Mechanical Advantage and Efficiency of Single and Double Purchase Winch Crab.
Theory: Winch crab is a kind of lifting m/c in which velocity ratio obtained by employing spur gears. This m/c. is
basically used on boats ships to raise starboard or tightening rope and on bridges and dam to operate lockage. These
are classified as:
1. Single purchase Winch crab.
2. Double purchase Winch Crab
Single Purchase Winch Crab :- It consists of two parallel spindles, upper one called effort spindle and lower one is
called as load spindle. One effort spindle a small touched wheel pinion is mounted in such a way that pinion and a
lever is attached to apply the effort. On load spindle, a large toothed wheel known as spur wheel is mounted in such
a way that pinion meshes with it. The load spindle also carries a cylinder of dia d. Both the spindles are suitably
mounted on a rigid frame. A rope is wound round the cylinder while load is attached on the other end,
Let,
P = Effort applied
W = load lifted
Tp = No. of teeth on pinion
Tw = No. of teeth on wheel
l = length of the lever arm
d = diameter of the cylinder
M. A. = W / P
Double Purchase Winch Crab :- In this case to obtain velocity ratio compound gear train is used, because
intermediately gears are compound wheel mounted on the same shaft. Other arrangements are similar to that of
single purchase winch crab.
Let,
T1 & T3 = No. of teeth on pinion.
T2 & T4 = No. of teeth on the spur wheels.
l = Length of the lever
d = Dia.of the load spindle
W = Load lifted,
P = Effort applied to lift the load, at the end of the handle.
For one revolution of lever, distance moved by effort is 2l,
No. of revolutions made by spur wheel of load spindle can be calculated by considering it a case of compound by
train.
Therefore No. of revolutions made by the pinion-1 = 1
And no. of revolutions made by the wheel-2 = T1 / T2 = revolution of pinion-3
And no. of revolutions made by the wheel-4 = T1xT3/T2xT4
Procedure:
1. Count the number of teeth of the pinion A and spur gear B.
2. Measure the circumference of pulley and of load drum with a string and meter rod or measure the
diameter with an outside caliper.
3. Wrap the string round the effort pulley and the other free end of the string will carry the effort.
4. Wrap another string round the load drum to carry load W in such a manner so that as the effort is
applied, the load is lifted up.
5. Suspend a load W on the string of the load drum and put the weights in the effort pan so that load
start moving up gradually.
6. Note down the values of W and P and calculate the M.A., V.R. and efficiency.
7. Increase the load W and again find the value of P.
8. In this way take at least six reading at different values of load.
9. Plot the graph between W & P and W & Efficiency.
10. Take W along horizontal axis.
11. Repeat the same procedure for double winch crab.
Observation:
M.A. = W/P
V.R. =
Efficiency = M.A./V.R
EXPERIMENT No. 10
Aim: To study the torsion testing machine and perform the torsion test.
Apparatus used: A torsion testing machine, twist meter for measuring angles of twist and a steel rule and calipers
or micrometer.
Theory: A torsion test is quite instrumental in determining the value of modulus of rigidity of a metallic specimen.
The value of modulus of rigidity can be found out thought observations made during the experiment by using the
torsion equation.
EXPERIMENT No. 11
Aim : To study the Rockwell Hardness testing machine and perform the Rockwell hardness test.
Apparatus: Rockwell Hardness testing machine, specimen of mild steel or other material.
Rockwell hardness tester presents direct reading of hardness number on a dial provided with the m/c.principally
this testing is similar to Brinell hardness testing. It differs only in
diameter and material ofthe indentor and the applied force. Although there are many scales
having different combinations of loadand size of indentor but commonly C scale is used and hardness
is presented as HRC. Here theindentor has a diamond cone at the tip and
applied force is of 150 kgf. Soft materials are often testedin B scale with a 1.6mm dia. Steel indentor at
60kgf.
SPECIFICATION OF HARDNESS TESTING M/C AND INDENTORS:-
A hardness test can be conducted can be conducted on Brinell testing m/c, Rockwell
hardnessm/c or vicker testing m/c. the specimen may be a cylinder, cube, thick or thin metallic sheet. ABrinell-
cum-Rocwell hardness testing m/c along with the specimen is shown in figure.
Procedure:
EXPERIMENT No. 12
Aim: To study the Brinell Hardness testing machine and the Brinell hardness test.
Apparatus: Brinell Hardness testing machine, specimen of mild steel / cast iron/ non
ferrous metals and Brinell microscope.
Procedure:
Observations and Calculations: Following observation are recorded from a test on steel specimenusing a
hardened steel ball as indentor.
BHN = Load Applied (kgf.)/ Spherical surface area indentation (in mm.)
= 2P/D(D-D2 d2)