Lab Progress Report EM

MCB 3023 ENGINEERING MATERIAL

LAB PROGRESS REPORT

GROUP 2

NAME: STUDENT ID

ESTRELLA MATUTINA OYONO ABANG

(LEADER)

15753

PATRICIO AGUILAR PINO 15755

DIONISIO MIGUEL NTUTUMU NSANG

15765

WONG HOONG WEI 15860

ARIFF HAKIMY B.MOHD KARIM

15868

LECTURER: Assoc Prof Dr Othman B Mamat

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Table of Contents

1. PROJECT BACKGROUND........................................................................................................3

1.1 Sample Description...................................................................................................................3

(a) Physical appearance.............................................................................................................3

(b) Size and Specification of The Sample..................................................................................4

(c) Mechanical characteristics....................................................................................................4

(d) Chemical Characteristics......................................................................................................4

(e) Optical characteristics..........................................................................................................4

1.2 Problem statement....................................................................................................................4

1.3 Objectives.................................................................................................................................5

1.4 Scopes.......................................................................................................................................5

2.0 LİTERATURE REVİEW..............................................................................................................6

3.0 METHODOLOGY.......................................................................................................................11

3.1 Small-size ASTM E8M Round Tension Test Specimen Procedures.....................................11

3.2 Project Activity.......................................................................................................................12

3.2.1 Task Assignment................................................................................................................12

3.2.2 Scheduling..........................................................................................................................12

3.2.3 Minute of Meeting..............................................................................................................13

3.3 Project Plan & Gantt Chart........................................................................................................16

3.4 Equipment...............................................................................................................................18

4.0 REFERENCE................................................................................................................................19

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1. PROJECT BACKGROUND

1.1 Sample Description

In order to accomplish the lab objectives, our group was assigned with three samples of

aluminum rods as per shown in Figure 1a. The sample shows the following characteristics:

Picture of our real sample:

Figure 1a: material sample

(a) Physical appearance

The colour of the sample is slightly dark grey. Figure 1b shows the shape and size of the

sample. It has two shoulders or grip sections and a gauge section between both shoulders.

The shoulders are large enough that they can be properly gripped. The gage section

presents a smaller cross-section so that failure and deformation can occur in this area

during testing.

Figure 1b: Sample Physical Appearance

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(b) Size and Specification of The Sample

Overall length = 10 cm

Distance between shoulders = 5 cm

Diameter/width of gage section = 0.6 cm

Diameter/width of grip section = 1 cm

(c) Mechanical characteristics

The aluminum rod presents a smooth and sensitively hard surface.

(d) Chemical Characteristics

No corrosion is present on the sample surface. Also the sample is free of oxidation.

(e) Optical characteristics

The sample is slightly shiny and it presents poor reflective characteristic. No transparent material.

1.2 Problem statement

Nowadays material availability is what makes our life different from our ancestors. Materials

are used in a vast field of activities such as construction and engineering industry. When in

service, materials are subjected to loads, forces, vibrations, etc. Therefore, it is very important to

know the characteristics and mechanical properties of any material before being selected for a

specific use. Knowing the material properties, we are able to make the correct choice when

determining the most suitable material needed for a specific task; in that way we can save

money, lives and ensure project success. The mechanical properties of material are determined

by performing several laboratory testing that simulate the real condition under which material

will be subjected while in use. Based on the physical shape and design of the sample assigned to

our group, the most suitable test to perform to determine the material properties is the tensile

test. The type of material, size and shape of the sample allow it to fix adequately in the UTM

(Universal Testing Machine) for tensile test, and several mechanical properties for aluminum can

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be determined from this testing. From the tensile test, we would like to acquire two mechanical

properties of the specimen which are strength and formability. An alternative testing we plan to

perform is the fatigue testing, this testing is proposed because the structure of our sample also

can be suitable for fatigue testing. Besides that, our specimens are also suitable for hardness

testing.

1.3 Objectives

The main objectives of this project are summarized in the following points:

i. To determine at least two of the mechanical properties of aluminium by conducting

mechanical lab testing using equipment available in the laboratory.

ii. To build the ability of organizing, leading, conducting and controlling material lab

testing experiment.

iii. To be able to analyse, evaluate and discuss results from mechanical testing of

material.

iv. To build up the ability of working in a team and to perform task within the given time.

v. To improve the ability of leading team work and also to be able to show obedience

and collaboration by doing each member of the team what is assigned to do.

1.4 Scopes

Aluminum is one of the most important and widely used metals in the transport, construction,

packaging and electrical sectors. Since aluminum is largely used in the industry, the main two

properties we will determine in this project by performing the tensile testing are:

Strength: Tensile strength (by tensile testing): also known as ultimate tensile strength is

the maximum stress under which the material can work before experiencing necking. This

property is very important because it ensure to avoid the material being used under load

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conditions that can lead to its failure. By comparing the ultimate tensile strength of

aluminium with the specification given by the design, we can know if it is safe to choose

aluminium for our design.

Stiffness: Modulus of Elasticity (by tensile testing): also known as Young Modulus is a measure of the stiffness of a material. It describes how material responds to stress applied or the material’s resistance to elastic deformation. The larger the modulus, the stiffer the specimen and the smaller the elastic strain that results from the applied stress. It is a significant factor to be considered during the design parameter for computing the elastic deformation of a specimen.

2.0 LİTERATURE REVİEW

Engineers are primarily concerned with the development and design of machines, structures and materials and the creation of new and better machines that can improve the existing ones. Better machine or material is one which is more economical in the overal cost of production and operation. These products are often subjected to diffrence kind of forces and load. Hence it is important to know the characteristeic of the material used and to design from which its deformation will not be execessive and to avoid fracture of the material. The properties of materials under the action of forces and deformations becomes an important engineering consideration.

The behavior of how a material reflect its relationship between its responce or deformation while load and force applied is refered as the mechanical properties of the material. In other words the properties that determine the behavior of engineering mats under applied forces. The most significant mechanical design properties are stiffness, strength, hardness,ductility and toughness. (Calister, 2011)This products also are made of basic materials that need to be tested in order to measure the characteristics and behaviour of their substances. This type of tests is called “material testing”. (Patel, 2014, para. 1). The mechanical properties of materials are verified by tests that replicate as similiar as possible to the service environment. Factors which should be considered include the nature of the applied load and its duration, as well as the environmental conditions. Standard test methods have been established by such national and international bodies as the International Organization for Standardization (ISO), with headquarters in Geneva, and the American Society for Testing and Materials (ASTM), Philadelphia. ( Kenneth, 2014,para. 1)

Aluminium is the second most common use of material for structual compare to steel. Structure made from aluminum is light and do not rust. It is commond to used for homeowner projects. It is now used to replace steel in many industry due to it is lighter, morec orrosion resistant, and a better conductor of heat and electricity. It is a good electrical conductor:it is ductile and can be readily cast and machined. It has a face-centered cubic (FCC) structure and a density of 2990kg/m3.

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In this course, we had been given 3 aluminum rod specimens for us to conduct the appropriate tests which could determine any two of the mechanical properties of the speciments. The specimens are made of aluminum and having a dog boned shape. The specimens have an average overall length of 10.00 cm; average distance between shoulders of 5.00 cm; average diameter/width of gage section = 0.60 cm; and average diameter/width of grip section of 1.00 cm. In order to find out the two mechanical properties of the specimens, we have decided to conduct a tensile test on the specimens given. This is simply because the specimens meet all the criteria to undergo tensile test and form the tensile test, we can produce yield strength for strength properties and also modulus of elasticity for stiffness property.

Tensile test:

Tensile test, which also known as tension test, perhaps is the most basic type of engineering mechanical test can perform on material for metals, polymers, composites, and others. Tension test is simple, relatively cheap, and fully standardized.(“Glosary of material testing”, 2014, para. 9). Tension test is commonly used to provide the most fundamental design information on the strength of materials and is an acceptance test for the specification of materials. The key parameters that describe the stress-strain curve obtained during the tension test are the tensile strength (UTS), yield strength or yield point (σy), elastic modulus (E), percent elongation (ΔL%) and the reduction in area (RA%). Toughness, Resilience, Poisson’s ratio (ν) can also be found by the use of this testing technique. (Gurbuz)

Test Specimen:

Small-size ASTM E8M Round Tension Test Specimen 3

In order to perform this test, 3 specimens as above are given. Tensile load is applied to the specimen until it fractures. When the specimen is exposed to a tensile loading, the specimen will undergo elastic and plastic deformation. Initially, the specimen will elastically deform giving a linear

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relationship of load and extension. The change in the gage length of the sample as pulling proceeds

is measured by extensometer. Elongation of the specimens and the load applied are recorded during the test. The Universal Testing Machine (UTM) uses extensometers to measure the elongation of the specimen up until necking, to measure the strain introduced on the specimen to calculate the engineering stress and strain. Engineering stress is then plotted against the engineering strain to acquire the tensile behavior of the specimens. Then the mechanical parameters that we search for can be found by studying on this curve.

By past necking, the Universal Testing Machine (UTM) acquires the strain data from the location of the crosshead. The load cell on the moving crosshead measured the vertical load applied to the specimen. The diameter of the gage on the specimen is measured by using vernier calipers, and from there the area is calculated by using Equation 1:

Equation 1

The engineering stress is a function of the force or load (N) applied and the original cross-

sectional area (m2) of the gage of the specimen. When a specimen is subjected to a tensile loading,

the metal will undergo elastic and plastic deformation. Initially, the metal will elastically deform giving a linear relationship of load and extension. These two parameters are then used for the calculation of the engineering stress and engineering strain to give a relationship as illustrated in Figure 2 using Equations 2 and 3 as follow:

Equation 2

Equation 3

Where:

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During elastic deformation, the engineering stress-strain relationship follows the Hook's Law

and the slope of the curve indicates the Young's modulus (E) Equation 4:

Equation 4

The tensile loading continues, yielding occurs at the beginning of plastic deformation. The yield stress, can be obtained by dividing the load at yielding (Py) by the original cross-sectional area of the specimen (Ao) as shown in Equation 5.

Equation 5

Aluminum is having a FCC crystal structure and does not show the definite yield point but it shows a smooth engineering stress strain curve. The yield strength therefore has to be calculated from the load at 0.2% strain divided by the original cross-sectional area as follows Equation 6 :

Equation 6

The determination of the yield strength at 0.2% offset or 0.2% strain can be carried out by drawing a straight line parallel to the slope of the stress-strain curve in the linear section, having an intersection on the x-axis at a strain equal to 0.002 as illustrated in Figure 3. An interception between the 0.2% offset line and the stress-strain curve represents the yield strength at 0.2% offset or 0.2% strain.

Figure 2- Aluminum Engineering Stress and Strain Diagram Figure 3- Yield Strength 0.2% offset

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Pass yielding, continuous loading will cause to an increment in the stress needed to permanently deform the specimen as shown in the engineering stress-strain curve. The specimen is strain hardened or work hardened. The degree of strain hardening based on the behavior of the deformed materials, crystal structure and chemical composition, which affects the dislocation motion. FCC structure materials having a high number of operating slip systems can easily slip and create a high density of dislocations. Tangling of these dislocations requires higher stress to uniformly and plastically deform the specimen, therefore resulting in strain hardening.

As the load is continuously applied, the stress-strain curve will achieve its maximum point,

which is the ultimate tensile strength At this point, the specimen can withstand the

highest stress before necking occur. This can be seen by a local reduction in the cross sectional area

of the specimen generally observed in the center of the gauge length as illustrated in Figure 4. After

necking, plastic deformation is not uniform and the stress decreases accordingly until fracture. The

fracture strength ( σ fracture) can be calculated from the load at fracture divided by the original

cross-sectional area, Ao, as expressed in Equation 7. (T. Udomphol)

Equation 7

Figure 4- Local reduction in the cross sectional area

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3.0 METHODOLOGY

3.1 Small-size ASTM E8M Round Tension Test Specimen Procedures

3.1.1 The specimen was measured with the callipers to determine the diameter of the cross

section.

3.1.2 A gage length of 30.00 mm and was marked on the specimen so that the distance between

the two marks could be measured after the tensile test was completed.

3.1.3 Universal Testing Machine (UTM) was set up in such that zero force would apply on the

specimen. The load cell was zeroed to ensure that the software only measured the tensile

load applied to the specimen.

3.1.4 The specimen was loaded into the jaws of the load frame.

3.1.5 The axial and transverse extensometers were attached to the reduced gage section of the

specimen, the axial extensometer was ensured that it was correctly set when mounting it

to the gage and that the transverse extensometer was across the complete diameter of the

specimen.

3.1.6 The load was released, and the extensometers were zeroed using the software.

3.1.7 The test was started, and the specimen was loaded, resulting in a measureable of strain.

3.1.8 The crosshead speed was set to 0.9 mm/min (0.015 mm/mm/min) at a specified state

beyond yielding.

3.1.9 The data was compiled by using the software, and transferred into a spread sheet.

3.1.20 The test was continued until fracture, where the software stopped the moving crosshead,

and finished compiling the data.

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3.2 Project Activity

3.2.1 Task Assignment- Patricio Aguilar and Ariff Hakimy : Literature Reviews- Dionisio Miguel : Project Background.- Estrella Matutina and Hoong Wei : Methodology

3.2.2 Scheduling

Date Time Agenda

22/05/2014 10.00 pm 1st Meeting

09/06/2014 10.00 pm 2nd Meeting

10/06/2014 10.30 am Lab Briefing Sessions

15/06/2014 10.00 pm 3rd Meeting

18/06/2014 10.00 pm 4th Meeting

25/06/2014 10.00 pm 5th Meeting

09/07/2014 10.00 pm Lab Progress Report Compile

10/07/2014 08.00 am Lab Progress Report Submission

11/07/2014 03.00 pm Lab Progress Report Viva/ Presentation

16/07/2014 03.00 pm Testing

18/07/2014 10.00 pm 6th Meeting

19/07/2014 10.00 pm Final Report Compile

21/07/2014 03.00 pm Final Report Submission

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3.2.3 Minute of Meeting

3.2.3.1 1st Meeting

Date: 22th May 2014

Venue: V3 Café, UTP

Objectives:

1. Ice Breaking Session2. To kick start the meeting of Engineering Material Lab Progress Report Activities3. Assign tasks to group members

TIME AGENDA:

10.00 pm Meeting was commenced by Estrella Matutina

10.05 pm 1. Ice Breaking Session

- All members had introduced themselves

1. Estrella Matutina being the group leader explained the purpose of having this meeting. She hoped we all could get along well and able to submit our work on time.

2. Assigning Tasks :

- Patricio Aguilar and Ariff Hakimy will be responsible for the Literature Reviews

- Dionisio Miguel will be responsible for the Project Background.- Estrella Matutina and Wong Hoong Wei will be responsible for the

Methodology of the progress report.11.00 pm Meeting adjourned.

3.2.3.2 2nd Meeting

Date: 9th June 2014


Objectives:

1. To discuss the selection of the Lab Briefing slots.

TIME AGENDA:

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10.05 pm 1. Lab Briefing Slots

- After discuss with the all members, we decided to attend the Lab Briefing Slot on Tuesday (10th July 2014) , 10.30am to 11.00am.

10.30 pm Meeting adjourned.

3.2.3.3 3rd Meeting

Date: 15th June 2014


Objectives:

1. To discuss regarding the testing specimen provided.2. To discuss the suitable mechanical properties of the specimen.3. To discuss the suitable testing method to be conducted.

TIME AGENDA:


10.05 pm 1. The specimens were examined by all the members.

2. We conclude that the specimen is made of aluminium and dog-bone shaped.

3. We decided to find the strength and formability mechanical properties of the specimen.

4. In order to find the two properties of the specimen, we will need to conduct the tensile test.

5. We decided to meet the technician in charge of Tensile Testing, Mr Paris B Mohd Said in Block 17 to acquire more information regarding the tensile test and the specimen.


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3.2.3.4 4th Meeting



Objectives:

1. To discuss regarding the testing specimen provided.2. To discuss the suitable testing method to be conducted.

TIME AGENDA:


10.05 pm 1. After consulting with Mr Mr Paris B Mohd Said, we are able to the tensile test on the specimen provided and we had also reserved a lab testing slot on week 9.

2. We had also acquired the ASTM Standard Test of Tensile Testing from the internet. From the ASTM Standard Test, we know that our specimen belongs to the Small-size ASTM E8M Round Tension Test.


3.2.3.5 5th Meeting



Objectives:

1. Remind members to submit their individual partsTIME AGENDA:


10.05 pm 1. Estrella reminded us to submit our parts on 9/07/2014 for Lab Progress Report Compilation.

2. Estrella hoped that we can all submit our part on time.11.30 pm Meeting adjourned.

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3.3 Project Plan & Gantt Chart

NO Week Task

1.1

(19-23/05/2014)

Meeting 1 Members introductory

2.4

(9-13/06/2014)

Get the sample Meeting 2 Review the lab briefing

3.4

(14-15/06/2014)

Meeting 3

Set work plan

Interpret and analyse the standard of the sample given

List and study the possible mechanical testing of the material

Complete the ‘Project Background’ part of the lab progress report

4.5

(16-20/06/2014)

Complete the ‘Literature Review’ part of the lab progress report

5.6

(23-27/06/2014)

Meeting 5

Complete the ‘Literature Review’ and ‘Methodology’ part of the lab progress report

6.8

(7-11/07/2014)

Complete the lab progress report

Compile the lab progress report

Submission of the lab progress report

Lab progress report viva/presentation

7. 9

(14-18/07/2014)

Meeting 6

Meeting lab 2 Testing

Complete the ‘Result and Discussion’ and ‘Conclusion’ part of the final report.

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Receive lab progress report feedback.

Final touch up of the final report

Compile the final report

8.10

(21-25/07/2014)

Submission of the final report

Prepare for the group presentation and individual VIVA

Gantt Chart :

Week 4

9-13

June

Week5

16-20

June

Week6

23-27

June

Week7

30-4

June/July

Week8

7-11

July

Week9

14-18

July

Week10

21-25

July

Sample

background

Standard

preparation

Literature

review

Methodology

Progress

report

submission

Testing

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Result and

discussion

Final report

submission

Viva

preparation

3.4 Equipment

Universal Testing Machine has two crossheads, one is adjusted for the length of the specimen and the

other one is driven to apply tension to the specimen.

This machine has a proper capability for the test specimen being tested. It has 4 main parameters:

force capability which provides the force to break the specimen, sped, precision and accuracy.

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4.0 REFERENCE

(ASTM), A. S. (2010). Standard Test Methods for Tension Tesing of Metallic Materials.

A simple Tension Test. (n.d.). Retrieved 07 09, 2014, from Experts Mind:

http://www.expertsmind.com/topic/theory-of-machines/a-simple-tension-test-919118.aspx

Calister, W. D. (2011). Material Science and Engineering . John Wiley & Sons (Asia) Pte Ltd.

Czichos, H. (2006). Springer Handbook of Materials Measurement Methods.

Favilla, S. (2010). Tensile Testing Laboratory.

Gurbuz, P. D. (n.d.). Tension Test. METU Department of Metallurgical And Material Engineering.

Instron. (n.d.). Featured Term - Tension Test. Retrieved 07 09, 2014, from Glossary of Materials

Testing Terms: http://www.instron.us/wa/glossary/default.aspx

Kenneth E. Hofer, J. (n.d.). Materials Testing. Retrieved 07 09, 2014, from Encyclopaedia Britannica:

http://global.britannica.com/EBchecked/topic/369090/materials-testing

Kevel, P. (2014). Machine design and industrial drafting.

T.Udomphol. (n.d.). Tensile Testing. Mechanical Metalhurgy Laboratory 431303.

Tensile Testing. (n.d.). Retrieved 07 09, 2014, from Wikipedia:

http://en.wikipedia.org/wiki/Tensile_testing

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Documents

Lab Progress Report EM