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ENGINEERING MATERIALS

LAB PROGRESS REPORT


MAY 2014

GROUP 27

Team Members:
Harrivin A/L Vijayakumaran
18639
Nixon Saw Hong Ken
18640
Lau Kah Mun
18651
Prasanth Raj A/L Baskaran
18676

Marwan Asyraaf
18681

TABLE OF CONTENTS

PROJECT BACKGROUND
Background of Sample
1
Problem Statement
2
Objective & Scope
2
LITERATURE REVIEW
Rockwell Test
Izod Test

3
3

METHODOLOGY
Tests Methods
Project Activities
Key Milestone & Gantt Chart
RESULT
Izod Test
Rockwell Test
DISCUSSION
Izod Impact Test
9
Rockwell Hardness Test
10
CONCLUSION
11
REFERENCES
12

5
7
7
8
8

APPENDICES
13

PROJECT BACKGROUND
Background of Sample
In this lab our group was given a sample as shown in Figure 1.1 and 1.2. The sample
is a carbon steel bar with groove at the top part. We can see that our sample has
the following characteristics:
Physical Appearance :
Three pieces of steel which are silver in colour and have a great amount of weight
relative to its size.

FIGURE 1
FIGURE 2
From both of the figure shown above , each of the specimen have similar
dimensions and the location of the groove is also the same. The dimensions are :
Size and specification : 75mm x 10 mm x 10mm
Short part before the groove = 27 mm
The specimen is in a solid state and have a very high hardness. It has a smooth
,shiny and reflective surface. The solid type of the specimen is opaque .

Problem Statement
The problem statement addresses the need to determine the mechanical
properties of objects assigned to us. We have to come out with at least 2 different
mechanical properties testing of the materials, which in our case is a metal bar
specimen. Limited to only 3 bars of specimen, we have thoroughly discussed during
the meeting and chose 2 suitable mechanical properties testing according to the
standard used by American Society of Testing and Materials(ASTM).
Hence, for this lab report our problem statement includes:
What are the mechanical properties of the given sample?
What are the tests needed to identify respective mechanical properties?
Objectives of the project are:
To identify 2 mechanical properties of the given sample by conducting relevant tests
To obtain valuable information about the mechanical behavior of the material

Scope

Testing according to ASTM standards

Mechanical properties of sample given

Procedures for Izod testing (impact test), and Rockwell hardness test

2
LITERATURE REVIEW
Rockwell Test
It enables the user to perform an accurate hardness test on a variety of sized parts
in just a few seconds.
Rockwell test methods for ASTM are defined by:
ASTM E18 Standard methods for Rockwell hardness and Rockwell superficial
hardness of metallic materials.
The indenter is either a diamond cone or steel ball, depending upon the
characteristics of the material being tested.
Strengths
1.

Rapid test, usually less than 10 seconds

2.

Direct readout, no questionable optical measurements required.

3.

Non-destructive, part normally can be used.

Weaknesses
1.

Multiple test scales (30) needed to cover the full range of metal hardness.

2.

Conversions between scales can be material dependant.

Samples must be clean and have a smooth test point to get good results

Izod Test (Impact Test)

Impact strength tests are used to measure a materials ability to withstand shock
loading (K.Budinski & M.Budinski, 2010). The Izod test is used more as a
comparative test rather than a definitive test.
ASTM standard for Izod testing is: ASTM E23 Standard Test Methods for Notched Bar
Impact Testing of
Metallic Materials
The Izod test involves striking a suitable test piece with a striker, mounted at the
end of a pendulum. The test piece is clamped vertically with the notch facing the
striker. The striker swings downwards impacting the test piece at the bottom of its
swing.

Figure 3: Schematic of the Izod impact test. Retrieved July 4, 2014 from
http://www.azom.com/article.aspx?ArticleID=2765

Factors Affecting Izod Impact Energy


Factors that affect the Izod impact energy of a specimen will include:

Yield strength and ductility

Notches

Temperature and strain rate

Fracture mechanism

METHODOLOGY
ROCKWELL HARDNESS TEST
a) APPARATUS
There are a few equipment required to do this type of mechanical test:
Rockwell Testing Machine:

The machine is used to apply force


onto the surface of the specimen. It then
measures the depth of indentation on the
surface of the specimen.

Indenter:

Sometimes called penetrator, it is the part


that will be in contact with the specimen
surface when the Rockwell Testing Machine
applies force onto the specimen. The
commonly used indenters are diamond cone
and steel sphere with a few fixed diameters.

Anvil:

A support element for the specimen to be


worked on. Care must be taken not to
damage the anvil in any way as it might
reduce accuracy of the result for the test
done on the specimen, especially for thin
specimen.

b) SIGNIFICANCE OF ROCKWELL HARDNESS TEST


Indentation hardness test could provide useful information about
metallic materials. This information may correlate to tensile strength,
wear resistance, ductility, and other physical characteristics of metallic
materials, and may be useful in quality control and selection of
materials. The results that will be recorded will be very useful as it give
much information as results obtained can be correlated with other
characteristic of materials.

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IZOD TEST
(a) APPARATUS
There are a few types of equipment and apparatus necessary for conducting
this test
Izod Impact Test Machine

Figure 4: UTP Rockwell Hardness


testing
Machine

: The Izod impact test machine is used with a


variety of pendulums in an energy capacity
range.

Pendulum

:Swinging pendulum of a known weight is


hoisted to a known height on the opposite
side of a pivot point. By calculating the
acceleration due to gravity (9.8 m/sec2), the
engineer knows that the weight falling from
a set height will contain a certain amount of
impact energy at the bottom of the swing.

Clamp

:To hold the material firmly with the notch


side facing the pendulums striking surface.

(c) SIGNIFICANCE OF IZOD TEST

: Notched Izod Impact is a single point test


that measures a materials resistance to
impact from a swinging pendulum. Izod
impact is defined as the kinetic energy
needed to initiate fracture and continue the
fracture until the specimen is broken. Izod
specimens are notched to prevent
deformation of the specimen upon impact.
This test can be used as a quick and easy
quality control check to determine if a
material meets specific impact properties or
to compare materials for general toughness.

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PROJECT
Figure
ACTIVITIES
5: UTP Izod Impact test
machine

DATE

18 JUNE 2014

23 JUNE 2014

6 JULY 2014

8 JULY 2014

22 JULY 2014

ACTIVITY
1. Collected specimen from lab technician
1. Had first group meeting at Information Resource Centre(IRC).
2. Discussed content of Lab Progress Report.
3. Divided tasks among group members.
1. Completed 1st draft of Lab Progress Report.
1. Lab Progress Report is presented to lecturer AP Dr. Othman
Mamat.
2. Booking of lab 17-00-04 for testing purposes.
3. Viva for Lab Progress Report
1. Izod Test and Brinell Test is carried out.
2. Data from tests is transferred to results section in lab report.

1. Second group meeting is held at Village 3 cafe to complete Lab


Final Report.
2. Discussion and conclusion of lab report id drafted out.
3. Task is divided among group members.

3 AUGUST
2014

7 AUGUST
1. Final Lab Report is completed.
2014
8 AUGUST
1. Submission of Final Lab Report.
2014
Gantt Chart & Key Milestone

Collect Specimen
First Meeting
Completion of Lab Progress Report 1st Draft
1st Lab Testing
Second Meeting
Completion of Lab Final Report
Submission of Lab Final Report

RESULTS
Izod test
Table 1: Data of Specimen & Testing
Equipment
DATE
SAMPLE
TESTING EQUIPMENT
ASTM
Standard Test

: 22/07/2014
: Mild Steel
: Amsler RKP 450
: ASTM E23
Methods

for Notched
Bar Impact
Testing of
Metallic

Table 2: Result of Izod test

Materials

Rockwell
Table 3: Data
& Testing
Table 4:
Rockwell
test

Sampl
e

Experiment

Swing
Angle(
)

Ap
(Joules
)

Avk
(Joules
)

contr
ol

150

299.7
51

111

80.92
8

80.016

108

85.08
3

84.179

61.94
1

60.994

Figure 6
3
Avera
ge

117

Sample

DATE
: 22/07/2014
SAMPLE
: Mild Steel
ROCKWELL SCALE
:B
TESTING EQUIPMENT : BREVETTI
AFFRI
INDENTOR TYPE
: 1/16 inch
Ball (B)
LOAD
: 100kgf
(981N)
TEMPERATURE
: 27 C
TYPE OF BALL
: Steel
ASTM
: ASTM E18
Standard
methods
for Rockwell
hardness
and Rockwell
superficial
hardness of
metallic
materials

75.98
4

Figure 7

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DISCUSSION

Av
(Joules
)

Test
of Specimen

Equipment
Result of
75.063
Hardness
Indentatio
HRB
n Point
Value
A

70.5

70.4

69.9

61.5

72.6

Average

70.0

Izod Impact Test

This discussion is based upon our observation on the Izod test that was conducted on the
three specimens of Mild Steel at a constant temperature and constant pendulum energy.
The pendulum energy used was controlled to 299.751 Joule and a swing angle of 150
was recorded when the sample was not placed in between the pendulum. Though the pendulum
energy was supposed to be at 300 Joules, a random error caused it to be at 299.751 Joules. ( Ap =
299.751 Joules )
The samples were placed on the Izod machine and the test was carried out one by one.
Their Av and Avk values were recorded at 80.928 J and 80.016 J respectively for the first sample.
85.083 J and 84.179 J for the second sample and for the third sample 61.941 J and 60.994 J .
From the Av and Avk values of each of the three samples there was a prominent
relationship in the angle of the pendulum after the impact. For the first sample the pendulum
swung up to 111 after the collusion with the sample. The second and third experiments recorded
108 and 117 respectively.
From this we can determine that there is an affiliation between the Av and Avk with the
angle of the pendulum swing, which is : The higher the value of Av and Avk , the lower the angle
of the pendulum swing after the impact. On average of the three samples, their Av and Avk were
75.948 Joules and 75.063 Joules.
Interpreting these data, it is obvious that when the pendulum exerts more force to break
the sample, there will be less energy to continue the momentum of the pendulum, thus reducing
its swing angle.
Possible source of error for this experiment include variation of testing conditions such as
temperature and humidity and striking location. Inhomogeneous or defective samples for
example inconsistencies in the notches. There is also a significant room for error of the testing
apparatus due to bearing friction and air resistance.

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Rockwell Hardness test

Another mechanical property that was tested is the hardness. The specimen
had already undergone Izod Impact Testing before the hardness of the specimen is
to be tested. The Rockwell hardness testing was carried out to inquire the hardness
value of the specimen.
For the test, a 1/16 inch ball indenter was used with a Rockwell hardness
scale B. Five indentations were made, two above the notch and three below.
Hardness values varied slightly among all 5 points with an average of 70 HRB.
The obtained results shows that there is slight differences or error between
the average hardness number and the standard average hardness number. This
error occurs due to several reasons that hindered the results during the experiment.
One of the reasons is that there is some space between the specimen and the
tested ground. This space occurs because of the Izod test that were being done
before that gives a little dent or curve to the surface of the specimen. Another
reason is that due to the dent that existed , the specimen was grinded using a
grinding machine to give a flatter surface. This may led to a change in the
microstructure of the specimen.
These errors however can still be reduced with the correct method. One of
the method is to use a specimen that had not been in any test previously in order
for it to have a flat surface. Moreover , when the specimen is to be grinded , it is
much better to do it by a machine that functions automatically which is more stable
and precise rather than using a hand manually.

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CONCLUSION
The experiments done were successful in a way that the two mechanical
properties of the given samples were identified and valuable information about the

mechanical behavior of the material of the samples were obtained. However, for
future tests, improvements are required to eliminate some of the errors mentioned.
Since there was space between the testing platform and the sample, the
sample should be grinded to perfection so that the samples surface is fully in
contact with the testing platform. More time should be spent on this experiment in
order to conduct more test to get the average results since there was time
constraints.
Samples undergo different conditions such as temperature and humidity,
thus, the samples ought to be kept at a designated place to avoid extreme
conditions from affecting its microstructure. Apart from that, grinding the sample
may cause some disruption to the samples microstructure. Therefore, it is
suggested that a professional should do the grinding more cautiously.
Lastly, the strength of tightening the sample for testing should be constant as
different tightening force might vary the impulsive force that acts onto the sample.
An average result should be taken from several tests that are made in order to get a
precise data.

11
REFERENCES
Budinski, K.G., & Budinski, M.K. (2010). Engineering Materials Properties and
Selection (9th edition). United States of America: Pearson Prentice Hall.
A to Z of Materials. http://www.azom.com/article.aspx?ArticleID=2765

12
APPENDICES

Figure 8: Uneven surface of the test sample before


Rockwell test being conducted on
Rockwell test. Light can be seen penetrating
between the sample and granite table

Figure 9:
sample

Figure 10: Sample after Izod test


Sample after all tests have been

Figure 11:
conducted.

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Sample minutes of meeting

ENGINEERING MATERIALS LAB GROUP 27


MINUTES OF MEETING 1
Date : 23 June 2014
Location: Information Resource Center
Start time: 3PM
Attendees

Present: Harrivin (Chair), Nixon Saw, Marwan Asyraaf, Lau Kah Mun, Prasanth Raj Baskaran.

Agenda Item
1. Determine requirements of
Lab Progress Report
2. Draft out Project
Background

3. Determine sources for


Literature Review

4. Determine tests to be
conducted and
methodology

Discussion

Action / Decision / Proposal

- Members contributed ideas on how to


complete the Lab Progress Report
- Discussion on how to determine Problem
Statement, Objective and Scope.
- Specimen was studied to find information
for Sample Background.
-Division of tasks

- 1st draft of Lab Progress Report is


started
-Lau Kah Mun was tasked with writing
out the Problem Statement, Objective
and Scope.
- Marwan Asyraaf was tasked with
writing out the Sample Background.

-Discussion on where to find sources for


Literature Review of sample.
- Internet and textbook deemed to be the
best resource.
-Division of tasks.
- Discussion on most suitable test to be
conducted with given sample.
- Izod test, Brinell test and microstructure
testing chosen.
-Methodology and tools required for each test
was looked up.
-Division of tasks.

- Nixon Saw tasked with writing out


Literature Review.

End Time: 5PM


Next Scheduled Meeting: 16 July 2014

14

- Prasanth Raj Baskaran tasked with


writing out the Methodology.

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