01: Tensile test on mild steel specimen performed on UTM (Universal Testing Machine)

Observations and calculations,

1. Specimen material: Mild steel

2. Initial diameter of specimen: 16 mm
3. Final diameter of specimen by the time of failure= 7 mm
4. Initial gauge length of specimen: 5 to 6 times the initial diameter= 16*5=80 mm
5. Final length of specimen= 22 mm
6. % of change in length of specimen= (Final length-Initial length/Initial length)*100 = (22-16/16)*100 = 37.5%
𝜋 𝜋
7. Initial area of specimen= *d2= *(16)^2= 3215.36 mm2
4 4
𝜋 𝜋
8. Final area of cross section of specimen by the time of failure= *d2= *(7)^2= 615.44 mm2
4 4
9. % of change in the area of cross section of specimen= )Initial area of cross section-Final area of cross section/Initial
area of cross section)*100= (3215.36-615.44/3215.36)*100= 80.85%
10. Load at Yield point= 112.3 kN
11. Load at Ultimate point= 137.45 kN
12. Stress acting at Yield point= Load acting at Yield point/Original area of cross section= 112.3/3215.36= 0.03492
kN/mm2
13. Stress acting at Ultimate point= Load acting at Ultimate point/Original area of cross section= 137.45/3215.36=
0.0427479 kN/mm2

Load vs Deflection readings,

Load, Corrected deflection

kN values, mm
1.75 79
1.8 79
1.8 83
1.85 83
1.65 87.8
1.7 87.8
5.4 87.8
6.45 87.9
10.2 87.98
12.8 87.99
16.45 88
19.6 88.1
22.95 88.12
26.5 88.13
30.65 88.14
34.7 88.15
37.95 88.16
42.3 88.17
44.95 88.18
48.2 88.19
51.6 88.2
56.85 88.21
62.25 88.22
67.75 88.23
70.55 88.24
 77.6 88.25
83 88.26
89.85 88.27
92.6 88.28
97.9 89
102.75 89.1
105.9 89.2
108.98 89.3
111.5 89.4
112.3 89.5
116.4 89.6
117.8 89.7
119.1 89.8
119.85 89.9
122.15 90
124.2 90.1
124.95 90.2
126.65 90.3
128.65 90.4
130.8 91
132.5 91.5
133.75 91.6
134.9 91.7
136.05 92
136.9 92.3
137.45 92.45
133.75 92.9
125.55 93
116.6 93.1
102.6 93.9
1.5 94

Graphs, Load, deflection, load vs deflection,

Load acting on specimen

160
140
120
100
80
60
40
20
0
1 4 7 10131619222528313437404346495255
 Corrected_deflection
values
100
95
90
85
80
75
70
1 5 9 1317212529333741454953

Load vs Deflection
150

100

50

0
1 5 9 1317212529333741454953

Load
Corrected_deflection values

***The End***
 02: Compression test on mild steel specimen performed on UTM (Universal Testing Machine)

Experimental set up,

Specimen diameter measure at two different places,

Length of specimen measuring,

Loading of specimen,
Load acting on specimen, load vs deflection readings set,

Load vs deflection graph,

Load vs deflection graph for

compression test performed on
brittle material
90
80
70
60
50
40
30
20
10
0
0 2000 4000 6000 8000
Observations,

1. Ultimate load acting on specimen by the time of failure= 6000*9.81 N= 58860 N or 58.86 kN.
2. Deflection by the time of failure= 77 mm.

***The End***
 3. Double Shear test on mild steel specimen

Machine set up for shear test,

Width and thickness measurement of specimen,

 Specimen loading on UTM with the help of fixture support,

Load acting and specimen failure,

Important observation table,

Observations,

1. Failure load= 5000 kg.

2. Double shear strength of specimen= 432.54 N/mm2

***The End***
 3. Bending test on mild steel specimen

Machine, equipment and apparatus,

Average diameter of specimen and calculations,

Length of specimen measure,

Marking for gauge length and total length of specimen,

Specimen loading in experimental set up, equipped with apparatus and measuring instruments,
Load acting, deflection measure at mid span, at point “A” and “B”,

Graphs, load vs deflection, at mid span of beam and points marked along length of beam and denoted as “A” and
“B”,

Load vs deflection, at mid span of beam and at marked points,

Point "A" and Point "B" on the beam........
1200
1000
800
600
400
200
0
1 2 3 4 5 6 7 8 9 10 11 12 13 14

Load Mid span deflection Point, "A" deflection

Point "B" Deflection Average deflection

Important observations and calculations,

1. Stress at Yield point, 491.27 MPa.

2. Modulus of Elasticity of material, 210.59 MPa.
3. Maximum deflection at mid span of beam, 1008 mm.
4. Maximum deflection at point “A”, 990 mm.
5. Maximum deflection at point “B”, 1110 mm.
6. Average deflection in beam, 1050 mm.
7. Maximum load sustaining capacity of beam without undergoing permanent deformation or failure, and still
showing maximum deflection is, 650*9.81= 6376.5 N.

***The End***
 4. Torsion test on mild steel

Machine, equipment and apparatus used,

Initial diameter measure of specimen,

Gauge length measure of specimen,

Specimen larking along straight fiber prior subjected to torsion,

Specimen loading in machine and subjected to torsional loading gradually,

Graph, torque vs angle of twist,

Important observations,

1. Failure torque, 1740 kg.m = 17069.4 N.m

2. Angle of twist where failure due to torque initiated or torque reached to maximum sustainable value/capacity of
material, 14.9 degrees.
3.

*** The End***

 5. Single shear test on mild steel specimen

Machine, equipment and apparatus,

Specimen diameter measurement,

Specimen loading on UTM by using jig,

Specimen load acting and shear failure,

Important observation table,

Important calculations and observations,

1. Failure load, 1550 kg= 1550*9.81= 15205.5 N.

2. Shear strength of specimen, 134.085 N.
3. Specimen diameter, 6.01 mm.

***The End***
 Simulation 01: Tensile test on the mild steel specimen (Ductile) using FEA

Specimen modelling, meshing and applying boundary conditions,

Red zone: Indicates the critical zone and failure leads to takes place in the same region due to inability of material to sustain
the load or load exceeds the yield limit.

Elongation in specimen under the action of uniformly applied and gradually increasing tensile load,

Failure in specimen when load exceeds the Yield limit,

Elongation leads specimen to lost material elasticity, load already exceeds the Yield limit and thus with little increase in load,
specimen further enters in zone of plasticity and finally specimen “Cup-Cone” failure occurs as at this point of move, specimen
is unable to sustain the applied load.

With load crosses Yield limit specimen enters into zone of plasticity and further followed by failure as at this point of move
load has already reached up to crossed the Ultimate Point.

Ductile material exhibits the point of elasticity, upper and lower yield point, ultimate point and point at which failure is
occurred due to formation of neck.
The screen shot below shows the failure of specimen in “Cup-Cone” manner. The failure is occurred as load is increased along
plane which is located 45 degree with respect to principal plane, at this point of move, normal load, increases the shear, and
shear will be maximum along plane which is at 45 degree location to principal plane and thus specimen failure occurred finally.

***The End***
 Simulation 02: Compression test on the Cast Iron (Brittle) specimen using FEA

Compression test on column/brick,

Load application, lateral buckling and failure,

Compression test on “Helical Spring” used in two wheeler or any general automobile vehicle (Light duty load
sustaining),

The steel is good in tensile or generally ductile material such as silver, copper, gold, steel are good in tension i.e. they can
draw into a wire.

The brittle material such as concrete, brick, Cast Iron are good in compression.
The following analysis done in Ansys shows the load acting on Helical Spring which popularly used in 2 Wheeler and
recommended for light duty load absorption. The screen shots below shows, modelling of spring, load acting, deformation in
spring and thus preferred zone of failure as virtue of load exceeds the maximum load sustaining capacity of material in
compression.

Spring modelling,

Meshing of spring,

Applying boundary conditions or fix up the location of spring in space/within Cartesian coordinate system,
Ansys result display and severity of failure at different locations,

Red zone in above screen shot represents the region of failure. The blue and green are safe zones and intensity of load acting
within these zone is within safe limit. The regions still carries the higher factor of safety and thus possibility of failure will
be pushes away.

***The End***