MECH-302 Mechanics of Materials

MECH302 Mechanics of Materials

Torsion Test of Hot-Rolled Steel Bar

Date Performed: 10/28/09 Date Submitted: 11/04/09

Names: Youssef Kobrianos Jeffery Roy Jason Fox Charles Hannon

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MECH-302 Mechanics of Materials

Objective: The objective of this lab is to obtain data necessary to draw the shear stress vs. shear strain ( vs. ) diagram for a bar of 1020 hot rolled steel, and to determine some important properties such as proportional limit, yield stress, maximum shear strength, the modulus of rigidity (shear modulus of elasticity, G), modulus of toughness and modulus of resilience.

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MECH-302 Mechanics of Materials

Discussion of Theory: Torsion testing is an integral part of machinery design; the effects of torsion can be seen in drive shafts or axles that are used in both machinery and vehicles. Torsion causes a shaft to twist resulting in a longitudinal deformation but not a circular deformation, Figure 1 demonstrates how shear stress will distort a sample. Shear stress () is defined as the internal torque (T) times the outer radius of the shaft (c) over the polar moment of inertia (J) (Equation 1). Shear stress for a solid shaft can also be defined as sixteen times the torque divided by times the diameter cubed (Equation 2). The polar moment of inertia can be defined as either divided by two times the outer radius of the shaft to the power of four (Equation 3) or divided by thirty-two multiplied by the diameter to the power of four (Equation 4).

(a) Figure 1

(b)

Equation 1 Equation 2 Equation 3 Equation 4

Shear strain () is a measure of angular distortion relative to a specimens initial conditions. It can be calculated for a solid shaft as the radius multiplied by the angle of twist in

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MECH-302 Mechanics of Materials

radians () divided by the length (Equation 5). The angle of twist is the amount that one end of a shaft twists with respect to the other end. The angle of twist can be found by multiplying the internal torque by the length and dividing by the polar moment of inertia times the shear modulus of elasticity or r modulus of rigidity (G) for the material used. The shear modulus of elasticity is a constant that is located in tables or manufacturer data sheets sheets.

Equation 5 Equation 6

Figure 2 Similarly to the tensile testing esting of steel, there exists as l linear-elastic elastic relationship for the elastic zone, or the initial portion of the shear stress stress-strain strain diagram seen in Figure 2. This relationship is denoted by the letter G (Equation 7) and is known as the shear modulus of elasticity, or modulus of resilience. It is an inherent quality of a given material which will necessarily vary between materials, and may even differ slightly between different specimens of the same material. Unlike tensile t testing, there exists little to no yield zone within the plastic region. The elastic zone exists from zero to the proportiona proportional limit, (pl,pl) and immediately after

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MECH-302 Mechanics of Materials

begins deforming plastically up to ultimate shear stress (u, u) and then eventually fractures at r,f.

Equation 7

Closely related to the modulus of rigidity is the shear modulus of resilience (usr). The shear modulus of resilience is defined as the area of the elastic zone, up to the proportional limit. The value of this area is used to describe the materials ability to withstand strain without permanent deformation. By strain hardening, this area of this region can be increased. The shear modulus of toughness (ust) describes a materials overall ability to distort without failing. The value of ust is defined as the entire area under the shear stress-strain curve. More ductile materials will generally have a greater shear modulus of toughness.

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MECH-302 Mechanics of Materials

Procedure: The equipment needed for a Torsion Test is a Tinius 10,000 in-lb torsion testing machine, a micrometer, and a troptometer. The micrometer is first used to measure the diameter of the 1020 hot rolled steel rod. Next a 10 inch gauge length is marked on the bar and the troptometer is installed on the bar. The bar is then placed into the torsion testing machine and secured firmly in the clamps. The distance between chucks in the torsion machine is measured, as it will be used as the gage length for the second portion of the experiment. The torsion machine is set to the highest scale and then both the machine and the troptometer are then zeroed. The sample is then loaded in increments of 200in-lb until the yield point is reached (approximately 2500 in-lb), and its corresponding angles of twist are recorded. Once the yield limit is reached the loading is stopped. The troptometer is removed, the sample is again loaded, and load readings are taken every 180 of rotation, this is continued until the sample reaches failure.

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MECH-302 Mechanics of Materials

Data & Results:

1018 Hot Rolled Steel 0.752 Initial Diameter (in) 10 Gage Length for Readings 0-15 21.65 Gage Length for Readings 16-39 Table 1 Specimen Dimensions Reading Torque Marks Angular Distortion [] 0 0.2 0.4 0.7 1 1.3 1.6 2 2.4 2.7 3 3.4 4 4.3 6.8 15.8 195.8 375.8 555.8 735.8 915.8 1095.8 1275.8 1455.8 1635.8 1815.8 Angular Distortion [radians] [radians] [psi] 0.0000 0.0000 0.00 0.0035 0.0001 2395.23 0.0070 0.0003 4790.45 0.0122 0.0005 7185.68 0.0175 0.0007 9580.91 0.0227 0.0009 11976.13 0.0279 0.0010 14371.36 0.0349 0.0013 16766.59 0.0419 0.0016 19161.81 0.0471 0.0018 21557.04 0.0524 0.0020 23952.26 0.0593 0.0022 26347.49 0.0698 0.0026 28742.72 0.0750 0.0028 31137.94 0.1187 0.0045 33533.17 0.2758 0.0104 34131.98 3.4174 0.0593 41317.66 6.5589 0.1139 48982.38 9.7005 0.1685 53772.83 12.8421 0.2230 57365.67 15.9837 0.2776 59760.90 19.1253 0.3322 61796.84 22.2669 0.3867 63353.74 25.4085 0.4413 64551.35 28.5501 0.4958 65748.97 31.6917 0.5504 66707.06
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0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25

[in-lbs] [0.2/mark] 0 0 200 1 400 2 600 3.5 800 5 1000 6.5 1200 8 1400 10 1600 12 1800 13.5 2000 15 2200 17 2400 20 2600 21.5 2800 34 2850 79 3450 4090 4490 4790 4990 5160 5290 5390 5490 5570

MECH-302 Mechanics of Materials

Reading Torque [in-lbs] 5650 5760 5880 5960 6100 6170 6260 6310 6410 6480 6630 6660 6710 5280

26 27 28 29 30 31 32 33 34 35 36 37 38 39

Angular Angular Distortion Distortion [0.2/mark] [] [radians] [radians] [psi] 1995.8 34.8333 0.6050 67665.15 2175.8 37.9749 0.6595 68982.52 2355.8 41.1165 0.7141 70419.66 2535.8 44.2581 0.7686 71377.75 2715.8 47.3997 0.8232 73054.41 2895.8 50.5412 0.8778 73892.74 3075.8 53.6828 0.9323 74970.59 3255.8 56.8244 0.9869 75569.40 3435.8 59.9660 1.0414 76767.01 3615.8 63.1076 1.0960 77605.34 3795.8 66.2492 1.1506 79401.76 3975.8 69.3908 1.2051 79761.04 4155.8 72.5324 1.2597 80359.85 4245.8 74.1032 1.2870 63233.98 Table 2 Experimental Data

Marks

Shear Stress vs. Shear Strain

90000.00 80000.00 70000.00 80359.85

(in*lbs)

60000.00 50000.00 40000.00 30000.00 20000.00 10000.00 0.00 0.0000 0.2000 0.4000 0.6000 0.8000 1.0000

63233.98

1.2000

1.4000

(in/in)
Chart 1 Shear Stress vs. Shear Strain

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MECH-302 Mechanics of Materials

= G ; G = 10.8x106 = 10.8x106() + 1960.9 R = 0.9906 35000.00 30000.00 25000.00

Elastic Region
31137.94 psi

(in*lbs)

20000.00 15000.00 10000.00 5000.00 0.00 0.0000 0.0005 0.0010 0.0015 0.0020 0.0025 0.0030

(in/in)
Chart 2 Elastic Region

Plastic Region
90000.00 80000.00 70000.00 80359.85 psi

(in*lbs)

60000.00 50000.00 40000.00 30000.00 20000.00 10000.00 0.00 0.0000 0.2000 0.4000 0.6000 0.8000 1.0000

63233.98

1.2000

1.4000

(in/in)
Chart 3 Plastic Region

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MECH-302 Mechanics of Materials

Proportional Limit Ultimate Shear Stress Failure Shear Stress Modulus of Rigidity Modulus of Resilience Modulus of Toughness

Material Properties Experimental Published 31137.94 psi 39908.93 80359.85 63233.98 10752 48.53 85571 psi psi ksi psi psi 50918.29 n/a 11600 n/a n/a

%difference -21.98 57.82 n/a -7.31 n/a n/a

Table 3 Discussion of Results: In previous shear testing it had been discovered through the use of four samples that ultimate shear stress (USS) was approximately 72.43% of ultimate tensile stress (UTS). As material data sheets with values specifically in terms of shear were not available, this previously found ratio was used to determine the published values for which to compare our experimental values. During the course of the experiment, the torsion machine malfunctioned between data points 26 and 27. There was slippage for some unknown reason, and the machine immediately began reading roughly 1350 in-lbs higher than it previously had been reading. For this reason, the data from points 27 through 39 have been adjusted downward linearly by 1350 in-lbs. The raw data and associated shear stress-strain diagram can be seen in the Appendix. The experimental modulus of rigidity was reasonably close to its published value. The experimental proportional limit, however, was not as close, and there existed a very large amount of error with the experimental ultimate shear stress. As it is known there was a machine malfunction prior to reaching USS, it is possible that our linear adjustment to these values was

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MECH-302 Mechanics of Materials

not sufficient. Given both experimental USS and the proportional limit were off by more than 20%, it is also possible that the machine had not been functioning properly for a longer period of time than was obviously visible between data points 26 and 27.

Conclusion: This lab exercise studied the twisting of a metal (1020 Hot-Rolled Steel) through several revolutions. The metal was slipping in the beginning but after applying some pressure it was secured. It was possible to plot the shear vs. strain diagrams, determine the proportional limit and modulus of rigidity, calculate the modulus of resilience and modulus of toughness, the yield stress and ultimate stress were also determined. Due to the obvious machine malfunction and the possibility of less obvious problems in functionality, further testing of the same material, possibly with another machine, would be necessary to achieve reliable data regarding its material properties.

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MECH-302 Mechanics of Materials

References I. II. Mechanics of Materials, Hibbeler. 7th edition, 2008 MECH 302, Mechanics of Materials, Wentworth Institute of Technology,

Prof. Masoud Olia III. IV. Shear Test of Multiple Shapes. Fox, Hannon, Kobrianos, Roy. 2009. Tensile Test of Steel for Stress vs. Strain Diagram. Fox, Hannon, Kobrianos, Roy. 2009. V. MatWeb, The online Materials Database. ASTM A607 Steel, grade 55, hot rolled. November 3, 2009. http://www.matweb.com/search/DataSheet.aspx?MatGUID=6c1640d1ba254c5b8cd9 57d854cc1f46

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MECH-302 Mechanics of Materials

Appendix

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MECH-302 Mechanics of Materials

ASTM A607 Steel, grade 55, hot rolled Metric English Mechanical Properties 70300 psi 485 MPa Tensile Strength, Ultimate 380 MPa 55100 psi Tensile Strength, Yield 20.00% 20.00% Elongation at Break 140 GPa 20300 ksi Bulk Modulus 80.0 GPa 11600 ksi Shear Modulus

Comments

In 50 mm Typical for steel Typical for steel

English Comments Component Elements Properties Metric 0.25% 0.25% Carbon, C 98.00% 98.00% Iron, Fe 1.35% 1.35% Manganese, Mn <= 0.040 % <= 0.040 % Phosphorous, P <= 0.050 % <= 0.050 % Sulfur, S ASTM A607 Steel, grade 55, hot rolled (MatWeb) Reading Torque Marks Angular Distortion [] 0 0.2 0.4 0.7 1 1.3 1.6 2 2.4 2.7 3 3.4 4 4.3 6.8 15.8 195.8 375.8 555.8 Angular Distortion [radians] 0.0000 0.0035 0.0070 0.0122 0.0175 0.0227 0.0279 0.0349 0.0419 0.0471 0.0524 0.0593 0.0698 0.0750 0.1187 0.2758 3.4174 6.5589 9.7005 [in/in] 0.0000 0.0001 0.0003 0.0005 0.0007 0.0009 0.0010 0.0013 0.0016 0.0018 0.0020 0.0022 0.0026 0.0028 0.0045 0.0104 0.0593 0.1139 0.1685 [psi] 0.00 2395.23 4790.45 7185.68 9580.91 11976.13 14371.36 16766.59 19161.81 21557.04 23952.26 26347.49 28742.72 31137.94 33533.17 34131.98 41317.66 48982.38 53772.83

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

[in*lbs] [0.2/mark] 0 0 200 1 400 2 600 3.5 800 5 1000 6.5 1200 8 1400 10 1600 12 1800 13.5 2000 15 2200 17 2400 20 2600 21.5 2800 34 2850 79 3450 4090 4490

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MECH-302 Mechanics of Materials

Reading Torque

19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39

Angular Distortion [in*lbs] [0.2/mark] [] 4790 735.8 4990 915.8 5160 1095.8 5290 1275.8 5390 1455.8 5490 1635.8 5570 1815.8 5650 1995.8 7110 2175.8 7230 2355.8 7310 2535.8 7450 2715.8 7520 2895.8 7610 3075.8 7660 3255.8 7760 3435.8 7830 3615.8 7980 3795.8 8010 3975.8 8060 4155.8 6630 4245.8

Marks

Angular Distortion [radians] 12.8421 15.9837 19.1253 22.2669 25.4085 28.5501 31.6917 34.8333 37.9749 41.1165 44.2581 47.3997 50.5412 53.6828 56.8244 59.9660 63.1076 66.2492 69.3908 72.5324 74.1032

[in/in] 0.2230 0.2776 0.3322 0.3867 0.4413 0.4958 0.5504 0.6050 0.6595 0.7141 0.7686 0.8232 0.8778 0.9323 0.9869 1.0414 1.0960 1.1506 1.2051 1.2597 1.2870

[psi] 57365.67 59760.90 61796.84 63353.74 64551.35 65748.97 66707.06 67665.15 85150.30 86587.44 87545.53 89222.19 90060.52 91138.37 91737.17 92934.79 93773.12 95569.54 95928.82 96527.63 79401.76

Raw Data Collected (Points that were later adjusted are highlighted)

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MECH-302 Mechanics of Materials

Shear Stress vs. Shear Strain

120000.00 100000.00 96527.63

(in*lbs)

80000.00 79401.76 60000.00 40000.00 20000.00 0.00 0.0000 0.2000 0.4000 0.6000 0.8000 1.0000 1.2000 1.4000

(in/in)
Shear Stress-Strain Diagram Using Unadjusted Data

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