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UNIVERSITI TENAGA NASIONAL

COLLEGE OF ENGINEERING
DEPARTMENT OF MECHANICAL ENGINEERING


MEMB221 - MECHANICS AND MATERIALS LAB
Sem 1 2014/2015

Experiment 2 : Torsion Testing
GROUP : MALIK AINUDDIN BIN AZMON (ME091149)
MEMBERS MUHAMAD ADIB BIN HALIM (ME091160)
AHMAD HAZIZI BIN ZULKIFLI (ME091148)
RANJANI VASU (ME 091074)
NOOR FAHMEEDA BINTI KUSYAIRI (ME 091169)

SECTION : 4
GROUP : 1
INSTRUCTOR : PUAN SITI ZUBAIDAH OTHMAN

Table of content

No. Contents No. of
Pages
1. Summary
2. Objective
3. Theory
4. Equipment and apparatus
5. Procedure
6. Data and Observations
7. Analysis and Results
8. Discussions
9. Conclusions
10. References


Summary

Objective
1. To understand the principle of torsion test
2. To determine the modulus of shear, G through measurement of the applied
torque and angle of twist

Theory

Torsion is a variation of pure shear wherein a structural member is twisted,
torsional forces produce a rotating motion about the longitudinal axis of one end
of the member relative to the other end. Torsion tests are normally performed on
cylindrical solids shaft of tube.
In each test, torque and twisting angle are measured to determine the shear
modulus, G. The shear modulus, G is obtained from the following formula:

and



Where;
T = torque
J = polar moment of inertia
G = shear modulus
= angle after application of torque
l = length
d = diameter
r = radius
Specimen made of various materials, with different diameters and lengths may be
investigated. The effective torque is recorded with the aid of a reference rod
equipped with strain gauges, the torque is directly displayed on a digital display of
a strain gauge measurement amplifier. This also incorporates important principles
of electronic measurement of mechanical values into the experimental program.
The unit is primarily intended for practical laboratory experiments.

Equipment and Apparatus
The apparatus consists mainly of:
1 Loading device with scale and revolution counter for twisting angle
measurement
2 Torque measurement unit
3 Calibration device
4 Specimen (mounted between the loading device and torque measurement
unit into hexagon socket)
5 Track base
6 Digital torque meter


Figure 1 : Layout of the torsion apparatus


Technical data
General data
Main dimension : 1400mm x 350mm x 300mm
Weight : 25kg

Loading device
Worm gear reduction ratio : 62
Revolution counter : 5 digit, with reset
Output scale : 360
Input scale : 360
Indicator : Adjustable

Torque measurement unit
Range : 0 30Nm
Display : 6 digit, LED 14mm
Temperature operating range : 0 - 50C
Power supply : 230V, 50/60Hz

Calibration device
Maximum load : 30Nm
Load increment : 2.5Nm


Loading Device

Figure 2 : Loading device
The torsional loading is transmitted to the specimen by a worm gear (1) and a
hand wheel (4). The teisting angle at the output and the input is read off by two
360 scales (2, 3). At the input side of the gear, there is in addition a 5-digit
revolution counter (5) which shows the input revolutions 1:1. The worm gear has
a reduction ratio of 62. The specimens hexagon ends are set into an axial
moveable socket (6) at the worm gear output side.


Torque measurement unit

Figure 3 : Torque measurement unit
In this testing, the torque will be measured by a reference torsion rod and strain
gauges. The specimen is mounted on one side to the loading device and on the
other side to the torque measurement device. The load torque applied to the
specimen produce shear stresses in the measurement torsion rod. These shear
stresses are proportional to the load torque. Strain gauges are used for detecting
the shear stresses.
Due to the reason that strain gauges can only measure strain but not twisting,
they must be applied in the direction of the maximum principal stress. In the case
of pure torsion, the maximum of principal stress will occur at a 45 angle to the
axial axis of the torsion rod.
Due to the arrangement of 4 strain gauges in the form of a full bridge circuit, the
distortion influence of additional bending and direct stresses is minimized. The
signal of the gauges is conditioned by a measuring amplifier with a digital read
out. The amplifier also delivers the supply of voltage for the bridge circuit.
The load torque will incur a slight deformation of the torsion rod. This will cause
an error in determining the twisting angle of the specimen. To prevent this error,
the specimen holder of the torque measurement unit is turnable. The
deformation can be compensated by a lever and a threaded spindle at the fixed
side of the torsion rod. The compensation can be controlled by a dial gauge at the
side of the specimen holder
.

Figure 4 : Dimensions of short trial rod (brass and aluminium)

Procedure
A. Calibration
For calibration of a torque measurement unit, a defined load torque is used as
reference. This reference load torque is generated by a calibration unit. The
calibration unit mainly consists of a lever and a load weight. The weight of the
lever is balanced by a certain counter weight. By that, the load torque only
depends on the load weight.
A wide range of torque between 0 and 30Nm can be set thanks a division into
weight discs. The resolution is 2.5N. The calibration unit must be clamped near by
the specimen holder of the torque measurement unit. The 15mm hexagon socket
was used to connect both the units.
To calibrate the torque measurement unit:
1. The read out of the amplifier was set to zero.
2. The torque measurement unit was connected to the measurement amplifier.
3. The measurement amplifier was switched on at the back.
4. The read outs were set to zero by pressing and holding the V and P buttons;
there should not be any load torque.
5. The load torque was increased in steps by 5Nm and the read outs were
recorded.
6. After each reload, the offsets were checked and were set back to zero when
necessary.
7. The read out values were corresponded to the applied load torque. The
noticed values of load torque and read out were graphed in a diagram.

Figure 5 : Calibration for the torque measurement unit

B. Performing the test
Mounting the specimen:
1. The short trial rod specimen is used in this test.
2. The specimen was mounted between the loading device and the torque-
measuring unit.
3. The 199mm hexagon socket was used.
4. The shifting holder of the load device was ensured to be in the mid position.
5. It was also ensured that there were no preload on the specimen. When
necessary, the hand wheel at the input of the worm gear was turned until the
read out of the amplifier was zero.
6. Both indicators at the input and output shaft of the worm gear were set to
zero.
7. The dial gauge of the compensation unit was set to zero. Then the turnable
scale was turned.
8. The revolution counter was reset.

Loading the specimen:
1. The hand wheel at the input of the gear was turned clockwise to load the
specimen. It was only turned for a defined angle increment.
2. For the first rotation, an increment of a quarter rotation (90) was chosen. For
the second and third rotation, an increment of half rotation (180) was chosen.
For the 4
th
to 10
th
rotation, an increment of one rotation (360) was chosen.
3. To calculate the twist angle at the specimen (output angle of the gear), the
rotations at the input was divided by the reduction ratio of 62.
4. Fracture will occur between 100 and 200 rotations.
5. The deformation of the measuring torsion rod was compensated after each
angle increment. The hand wheel of the compensation unit was turned until
the dial gauge indicated zero.
6. The torque value was read from the display of the amplifier and it was noted
together with the indicated twist angle.
7. The result was tabulated.
8. The experiment was then repeated with the other test specimen of a different
material.

Data and Observations
A.Calibration
Length of lever bar = 0.5m
Load (Nm) Applied Load Torque
(Nm)
Read out Load Torque
(Nm)
5 2.50 2.30
10 5.00 4.55
15 7.50 6.75
20 10.00 9.05
25 12.50 11.40
30 15.00 13.70

Table 1 : Readings for the Calibration Test
B.Test results

Material : Aluminium
Diameter : 6.58mm
Length : 120.70mm

Rotation Angle at gear input
()
Angle of Twist () Read out Torque
(Nm)
1
st
90 1.45 0.50
180 2.90 1.15
270 4.35 1.95
360 5.80 2.85
2
nd
540 8.71 3.35
720 11.61 5.00
3
rd
900 14.52 7.35
1080 17.42 9.80
4
th
1440 23.23 9.55
5
th
1800 29.03 10.05
6
th
2160 34.84 10.45
7
th
2520 40.65 10.65
8
th
2880 46.45 10.90
9
th
3240 52.26 11.05
10
th
3600 58.06 11.25

Table 2 : Results for Aluminium Test


Material : Brass
Diameter : 6.96mm
Length : 121.98mm

Rotation Angle at gear input
()
Angle of Twist () Read out Torque
(Nm)
1
st
90 1.45 0.35
180 2.90 0.80
270 4.35 1.75
360 5.80 2.90
2
nd
540 8.71 4.90
720 11.61 6.80
3
rd
900 14.52 7.95
1080 17.42 8.70
4
th
1440 23.23 9.55
5
th
1800 29.03 10.05
6
th
2160 34.84 10.45
7
th
2520 40.65 10.65
8
th
2880 46.45 10.90
9
th
3240 52.26 11.05
10
th
3600 58.06 11.25

Table 3 : Results for Brass Test
ANALYSIS AND RESULTS

a) Graph of amplifier torque value against applied torque value.











y = 0.9126x - 0.0267
0
2
4
6
8
10
12
14
16
0 2 4 6 8 10 12 14 16
A
m
p
l
i
f
i
e
d

T
o
r
q
u
e
,

N
m

Applied load torque, Nm
Amplified torque vs Applied load torque
Applied Load Torque
(Nm)
Read out Load Torque
(Nm)
2.50 2.30
5.00 4.55
7.50 6.75
10.00 9.05
12.50 11.40
15.00 13.70
b) Graph of Load Torque vs Revolution for Aluminium
Output Angle
()
Output Angle
(rad)
Read out Torque
(Nm)
1.45 0.025 0.50
2.90 0.051 1.15
4.35 0.076 1.95
5.80 0.101 2.85
8.71 0.152 3.35
11.61 0.203 5.00
14.52 0.253 7.35
17.42 0.304 9.80
23.23 0.405 9.55
29.03 0.507 10.05
34.84 0.608 10.45
40.65 0.709 10.65
46.45 0.811 10.90
52.26 0.912 11.05
58.06 1.013 11.25


0
2
4
6
8
10
12
0 0.2 0.4 0.6 0.8 1 1.2
L
o
a
d

t
o
r
q
u
e

N
m

Revolution of radian
Load Torque vs Revolution
c) Graph of Load Torque vs. Revolution for Brass
Output Angle
()
Output Angle
(rad)
Load torque
(Nm)
1.45 0.025 0.35
2.90 0.051 0.80
4.35 0.076 1.75
5.80 0.101 2.90
8.70 0.152 4.90
11.61 0.203 6.80
14.51 0.253 7.95
17.42 0.304 8.70
23.22 0.405 9.55
29.03 0.507 10.05
34.84 0.608 10.45
40.65 0.709 10.65
46.45 0.811 10.90
52.26 0.912 11.05
58.06 1.013 11.25


0
2
4
6
8
10
12
0 0.2 0.4 0.6 0.8 1 1.2
L
o
a
d

T
o
r
q
u
e

N
m

Revolution (rad)
Load Torque vs Revolution
SAMPLE CALCULATION
1) Calibration Curve
Refer to Calibration Curve
Gradient =

= 0.9133
Theoretical value = 1.000
Percentage difference =



=


= 8.67%

2) Shear modulus of Aluminium
Diameter of specimen, d = 6.58 mm
= 6.58 x

m

Length of specimen, L = 120.70 mm
= 0.1207 m

Polar moment of inertia, J =


=1.84 x


Twist angle is obtained by dividing the rotations at the input gear by the reduction ratio of 62.
Twist Angle, =

= 0.025 rad

Slope from the graph, T/ =


= 13.52 Nm/ rad
Shear modulus,


= 8.87 GPa

= 10.7 GPa
Percentage error = [


] x 100%
=


=17.10 %
Torque ( Nm)

= 11.25


= 1.65 Nm

Percentage error = [


] x 100%
=

x 100 %
= 581 %


3) Shear modulus of Brass
Diameter of specimen, d = 6.96 mm
= 6.96 x

m

Length of specimen, L = 121.98 mm
= 0.12198 m

Polar moment of inertia, J =


=2.3 x


Twist angle is obtained by dividing the rotations at the input gear by the reduction ratio of 62.
Twist Angle, =

= 0.025 rad

Slope from the graph, T/ =


= 8.07Nm/ rad

Shear modulus,


= 4.28 GPa

= 8.3 GPa
Percentage error = [


] x 100%
=


= 48.43 %

Torque ( Nm)

= 11.25 Nm


= 0.82 Nm

Percentage error = [


] x 100%
=

x 100 %
= 92.71


DISCUSSION
From the first graph, we can see that the applied load torque is directly proportional to the
read out amplifier with a gradient of 0.9126. When the value of the applied load decreases, the
value of the read out amplifier also decreases.

With the help of the equation obtained from the calibration curve, the actual load torque
value is calculated and checked for percentage different. Since the percentage difference of the
load torque is relatively low, the graph of Load Torque vs. Revolution in radian at the gear
output is plotted using the value obtained from the read out amplifier. The gradient of the graph
for both aluminium and brass specimen is then calculated.

Using the values obtained, the shear modulus, G was then calculated. The experimental
shear modulus,

for aluminium is 8.87 GPa. This experimental value has a percentage error
of 17.10% when it is compared with the theoretical shear modulus of aluminium which is 10.7
GPa. For brass on the other hand, the experimental shear modulus,

is 4.28 GPa while the


percentage error calculated is 48.43% when compared with the theoretical shear modulus of
brass which is 8.3 GPa. These errors occurs due to some factors such as

Systemic error.
This error is usually caused by the apparatus that was not calibrated properly. Thus, readings
obtained will deviate from the theoretical values.
Human error.
This kind of error is usually caused by the students who lack of skills to operate the torsion
apparatus as well as the dial gauge. Besides that, errors also might occur due to student
miscalculation of the values as well as the uncertainty of analysis method.
Parallax error while taking readings.
Variation that might occur in materials properties


Stiffness of a specimen can be determines by its value of shear modulus. In this
experiment, the value of shear modulus for brass is higher than aluminium thus brass is stiffer
than aluminium. It can also be concluded that brass is a brittle while aluminium is more ductile.
The common mechanical parts that is usually subjected to torsional force are :
Crank shaft of a car engine system
Door hinge
Crane
Wrench
Car jack where torsion force is needed to expand and contract.

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