Adhere to following instructions while writing

the report.

1. Report to be submitted in Flat file only.

2. Use A4 papers only with following margin:

Top, Bottom and Righ - 1 cm, Left - 1.5 cm

3. Use the Name plate as given in this page below while

writing name, subject etc. in BLOCK LETTERS on the
cover of Flat file.

4. Stick to the format given in this report.

5. You can add your own words without deviating from

the objective of any experiment in the report.

6. Make diagrams and sketches following engineering

standard, not artistic one.

7. Staple each experiment report at left corner before

putting into the flat file.

8. If got any doubt, clarify it before making a wrong

move.

ABS ACADEMY OF POLYTECHNIC

DEPARTMENT: ………. YEAR: ….......................... SEMESTER: ……..

NAME: ………………………………………………… SERIAL NO. ……..

SUBJECT: ………………………………………………………………………

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 INDEX

List of Experiment Page

1. Rockwell hardness Test on Hardened Steel ………………...

2. Brinell Hardness Test on Mild Steel ………………………..

3. Tension Test on mild steel on Universal Testing Machine …

4. Izod Impact tests of a standard specimen …………………...

5. Torsion Test on Mild steel bar ………………………………

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EXPERIMENT NO. – 01 DATE:DD/MM/YYYY

AIM: To study the Rockwell Hardness testing machine and perform the Rockwell hardness test.

APPARAUTS: Rockwell Hardness testing machine, indenter and test specimen.

THEORY: Hardness represents the resistance of material surface to abrasion, scratching and
cutting. The testing method is guided by IS 1586:2000 standard. In all hardness tests,
a definite force is mechanically applied on the piece through an indenter. Common indenter are
made of hardened steel or diamond. Rockwell hardness tester presents direct reading of
hardness number on a dial provided with the machine. Principally this testing is similar to
Brinell hardness testing. It differs only in diameter and material of the indenter and the applied
force. Although there are many scales having different combinations of load and size of
indenter but commonly ‘C’ scale is used and hardness is presented as HRC. Here the indenter
has a diamond cone (Brale) at the tip and applied force is of 150 kgf. Soft materials are often
tested in ‘B’ scale with a 1.587 mm dia. steel ball indenter at 100kgf. There is also an 'A' scale
that uses a cone indenter.

SPECIFICATION OF HARDNESS TESTING M/C AND INDENTORS:

PROCEDURE:
1. Identify the material of the given specimen.
2. Know the major load, type of indenter and scale to be used for the given test specimen
from the table given with Rockwell testing machine.
3. Fix the indenter and place the given specimen on the anvil of the machine.
4. Select the major load from the knob available on the right of the machine.
5. Raise the anvil using the hand wheel till the specimen touches the indenter and then
slowly turn the wheel till the small pointer on the dial reaches the red mark position.

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 Now the specimen is subjected to a minor load of 10kg.
6. Push the loading handle in the forward direction to apply the major load to the specimen
and allow the load to act on the specimen for 15 seconds.
7. Release the major load by pushing the loading handle in the backward direction and
keep the minor 10kg load still on the specimen.
8. Read the Rockwell hardness number either from ‘C’ or ‘B’ scale, as the case may be,
from the dial and record it.
9. Release the minor load of 10kg by rotating the hand wheel and lowering the screw bar.
10. Repeat the experiment to obtain at least 3 different sets of observations.

PRECAUTIONS:
1. The specimen should be cleaned properly.
2. For the given specimen a gap of at least 3mm between any two adjacent indentations
and 1.5mm from the edge has to be provided.
3. Load must be applied gradually.

OBSERVATION:
Specimen used: Unalloyed Steel.
Sl. Major load Indenter Scale Hardness Number (HRB)
No. (kgf)
1. 100 1.587 dia. Steel ball B 91

2. 100 '' B 90

3. 100 '' B 91
Average Rockwell Hardness Number 90.66

CONCLUSION: For the given steel specimen, determined hardness is HRB 90.66.

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EXPERIMENT NO. – 02 DATE:DD/MM/YYYY

AIM: To study the Brinell Hardness testing machine and the Brinell hardness test..

APPARAUTS: Brinell Hardness testing machine, specimen and Brinell microscope.

THEORY: Hardness represents the resistance of material surface to abrasion, scratching and
cutting, hardness after gives clear identification of strength. In all hardness testes, a
define force is mechanically applied on the test piece for about 15 seconds. The indenter, which
transmits the load to the test piece, varies in size and shape for different testes. Common
indenters are made of hardened steel or diamond. In Brinell hardness testing, steel balls are used
as indenter. Diameter of the indenter and the applied force depend upon the thickness of the test
specimen, because for accurate results, depth of indentation should be less than 1/8th of the
thickness of the test pieces. According to the thickness of the test piece increase, the diameter of
the indenter and force are changed. Brinell Hardness testing is guided by IS:1500.

SPECIFICATION OF HARDNESS TESTING M/C AND INDENTORS:

Its specification are as follows:
Ability to determine hardness up to 500BHN.
Diameter of ball (as indenter) used D = 2.5mm, 5mm, 10mm.
Maximum application load = 3000kgf.
Method of load application = Lever type
Capability of testing the lower hardness range = 1 BHN on application of 0.5D2 load.

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PROCEDURE:
1. Insert ball of dia ‘D’ in ball holder of the m/c.
2. Make the specimen surface clean by removing dust, dirt, oil and grease etc.
3. Make contact between the specimen surface and the ball by rotating the jack adjusting
wheel.
4. Apply the minor load by rotating hand wheel.
5. Pull the load release level and wait for minimum 15 second. The load will automatically
apply gradually.
6. Remove the specimen from support table and locate the indentation so made. View the
indentation through microscope and measure the diameter ‘d’ by micrometer fitted on
microscope.
7. Calculate the hardness number by following formula.

8. Repeat the entire operation, 3-times.

PRECAUTIONS:
1. The specimen should be clean properly.
2. Take reading more carefully and correctly.
3. Place the specimen properly.
4. Move Jack adjusting wheel slowly.
5. After applying load remove the load gradually on time.

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OBSERVATION:
Specimen used: Steel Specimen.
Sl. Ball Dia. Applied Load (P) Dia. Of Indentation (d) P/D2 Hardness
No. (mm) (kgf) (mm) (kg/mm2) Number (BHN)
1. 10 3000 3.6 30 285

2. 10 3000 3.7 30 269

3. 10 3000 3.6 30 285

Average Brinell Hardness Number 279.66

CONCLUSION: For the given steel specimen determined hardness is BHN 279.66

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EXPERIMENT NO. – 03 DATE:DD/MM/YYYY
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 applications. For safe design of these components, their ultimate tensile
strength and ductility has 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 and 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.

ABOUT OF UTM & ITS SPECIFICATIONS:

The tensile test is conducted on UTM. It is hydraulically operated by a pump. The left has
upper, middle and lower cross heads that is specimen grips (or jaws). Idle cross head can be
moved up and down for adjustment. The pipes connecting the left and right parts are oil pipes
through which the pumped oil under pressure flows on left parts to move the cross-heads. The
UTM at our disposal is a digital one. Here two valves; one for flow control and another for
pressure regulation are present and by operating these valves loading and unloading of the
machine is done. Testing in UTM is guided by IS 1608:2005

SPECIFICATIONS :-
1. Type: Digital
2. Load capacity: 400kN
3. Least count = 10N.
4. Power supply = 440V 3phase

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PROCEDURE:
1. The load indicator is set at zero by adjusting the initial setting.
2. Measure the diameter of the test piece by vernier caliper at least at three places
anddetermine the mean value. Also mark the gauge length (equals to 5D).
3. Now the specimen is gripped between upper and middle cross head jaws.
4. Set the automatic graph recording system.
5. Start the m/c and take the reading.
6. The specimen is loaded gradually and the elongation is noted until the specimen breaks.

PRECAUTIONS:
1. The specimen should be prepared in proper dimensions.
2. The specimen should be properly fixed between the jaws.
3. Take reading carefully.
4. After breaking specimen stop the m/c, release the load and bring valve positions to initial.

OBSEVATION:
Specimen used: Annealed Mild Steel.
(I) Initial diameter of specimen d1 = 15 mm

(II) Initial gauge length of specimen L1 = 75 mm

(III) Initial cross-section area of specimen A1 = 176.7 mm2

(IV) Load of yield point Ft. = 44.2 kN

(V) Ultimate load before specimen breaking F = 80 kN

(VI) Final length after specimen breaking L2 = 91.5 mm

(VII) Dia. Of specimen at breaking place d2 = 10.1 mm

(VIII) Cross section area at breaking place A2 = 80.1 mm2

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Load vs. Elongation graph

Calculation:
Tensile Strength = Maximum Load / Original cross sectional area
= F / A1
= 80000 / 176.7
= 453 N/mm2 or Mpa
Percentage Elongation = Change in length / Initial Length *100%
= (L2-L1 / L1)*100%
= (91.5-75 / 75)*100%
= 22%

CONCLUSION: Above experiment shows that the specimen had a tensile strength of 453
newtons per square millimeter and a percentage elongation of 22%. These results indicate that
mild steel has relatively high tensile strength and ductility.

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EXPERIMENT NO. – 04 DATE:DD/MM/YYYY
AIM: To determine the impact strength of the given specimen by conducting Izod impact test.

APPARATUS: Impact testing machine with attachment for Izod test, Given specimen,
Verniercaliper & Scale.

THEORY: In manufacturing locomotive wheels, coins, connecting rods etc. the components
are subjected to impact (shock) loads. These loads are applied suddenly. The stress
induced in these components are many times more than the stress produced by gradual loading.
Therefore, impact tests are performed to asses shock absorbing capacity of materials subjected
to suddenly applied loads. These capabilities are expressed as (i) Rupture energy (ii) Modulus
of rupture and (iii) Notch impact strength.

Two types of notch impact tests are commonly-

1. Charpy test
2. Izod test
In Izod test, the specimen is placed as ‘cantilever beam’. The specimens have V-shaped notch of
45°. U-shaped notch is also common. The notch is located on tension side of specimen during
impact loading. Depth of notch is generally taken as t/5 to t/3 where ‘t’ is thickness of the
specimen. This test is guided by IS 1598:1977.

SPECIFICATION OF M/C AND SPECIMEN DETAILS:

Its specifications along-with their typical values are as follows -

• Impact capacity = 164joule

• Least count of capacity (dial) scale = 2joule Izod Impact Testing Machine
• Weight of striking hammer = 18.7 kg. with Notch detail
• Swing diameter of hammer = 1600mm.
• Angle of hammer before striking = 90°
• Striking velocity of hammer = 5.6m/sec.
• Specimen size = 75x10x10 mm.
• Type of notch = V-notch
• Angle of notch = 45°
• Depth of notch = 2 mm.

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PROCEDURE:
1. Lift the hammer to an appropriate knife edge position and notch the energy stored in the
hammer. For the standard Izod test the energy stored should be 164j.
2. Locate the test specimen on the m/c supports.
3. Release the hammer. The hammer will break the piece and shoot up the other side of the
specimen.
4. Note the residual energy indicated on the scale by the hammer.
5. Impact strength of the test specimen is the difference of the initial energy stored in
hammer and the residual energy.

PRECAUTIONS:
1. The specimen should be prepared in proper dimensions.
2. Take reading more frequently.
3. Make the loose pointer in contact with the fixed pointer after setting the pendulum.
4. Do not stand in front of swinging hammer or releasing hammer.
5. Place the specimen in proper position.

OBSERVATION:
Specimen used – Mild Steel
Area of the Notched portion = Width x Depth = 10 x (10-2) = 80 mm2
Notch Impact Strength of the Specimen is = Total energy absorbed / Notch area
SL. Initial Energy Residual Energy Absorb Energy (E1-E2) Notch Impact
NO (E1) in joule (E2)in joule in joule Strength Joule/mm2
.
1. 164 76 88 1.1
2. 164 72 92 1.15
3. 164 75 89 1.1

CONCLUSION: Notch impact strength of the given mild steel specimen is found as 1.2 j/mm2

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EXPERIMENT NO. – 05 DATE:DD/MM/YYYY

AIM: Torsion Test on Mild steel bar.

APPARATUS: A torsion testing machine, Twist meter for measuring angles of twist, a steel
rule and Vernier Caliper 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

PROCEDURE:

1. Select the driving dogs to suit the size of the specimen and clamp it in the machine by adjusting the
length of the specimen by means of a sliding spindle.
2. Measure the diameter at about three places and take the average value.
3. Choose the appropriate range by capacity change lever.
4. Set the maximum load pointer to zero.
5. Set the protector to zero for convenience and clamp it by means of knurled screw.
6. Carry out straining by rotating the hand wheel in either direction.
7. Load the machine in suitable increments.
8. Then load out to failure as to cause equal increments of strain reading.
9. Plot a torque- twist (T- θ) graph.
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 10. Read off co-ordinates of a convenient point from the straight line portion of the torque twist (T- θ)
graph and calculate the value of G by using relation.

PRECAUTION:
1) Measure the dimensions of the specimen carefully.
2) Measure the Angle of twist accurately for the corresponding value of Torque.

OBSERVATION:
Average diameter of the sample d =11.17 mm
Length of the sample l =190 mm
Polar moment of Inertia J = πd4/32 = 1528.31 mm4
Typical torque (Nm) vs twist angle (degrees):
Torque Angle of Torque Angle of Torque Angle of
(N-m) Twist (deg.) (N-m) Twist (deg.) (N-m) Twist (deg.)
0 0 62.78 21 123.7 700
0.98 1 62.78 24 127.2 800
1.96 2 62.78 27 130.47 900
3.92 3 62.78 30 133.42 1000
5.89 4 66.71 60 137.34 1200
14.72 5 71.61 90 141.26 1400
23.54 6 78.48 120 142.25 1500
30.41 7 83.39 150 145.19 1600
37.28 8 87.31 180 145.19 1700
43.16 9 92.21 210 147.15 1800
51.99 10 96.14 240 147.15 1830
58.56 11 99.08 270 147.15 1860
62.78 12 102.02 300 148.13 1890
62.78 13 106.5 350 148.13 1920
62.78 14 109.3 400 148.62 1950
63.77 15 113.8 450 149.11 1980
63.77 16 116.7 500 149.11 2010
63.77 18 120.66 600 149.11 2040

Typical plot of Torque vs Angle of twist:

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Yield torque Tyield = 62.78 Nm (observed from plot)
.

Yield stress = [Tyield × (d/2)]/J = 62.78 ∗ 1000 ∗ ∗ = 229.42 Mpa
  .

Torque at Rupture Trupture = 149.11 Nm (observed from plot)

.

Modulus of rupture = [Trupture × (d/2)]/ J = 149.11 ∗ 1000 ∗ ∗ = 544.90 MPa
  .

Slope at linear portion of the graph within elastic limit:

Slope of torque vs twist plot T/ = 443.17 Nm/rad


Modulus of rigidity G = (T/θ) × (l/J) = 443.17*1000*  . = 55.09 GPa

CONCLUSION: Modulus of rigidity of tested mild steel specimen is as high as 55.09 GPa.

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