Experiment 1: Strain Gauge

Aim:
To experience and understand the application of a strain gauge in
determining strains and forces within loaded structures. To compare strain
gauge values of a loaded cantilever beam to calculated theoretical values
during a calibration process. Using a calibrated strain gauge to determine
an unknown load.
Introduction:
Strain gauges are useful devices in engineering to determines strains and
stresses in structures. They are bonded to the surfaces of a structure and
when the structure experiences strain the material either reduces or
increases in surface area therefore stretching or compressing the strain
gauge. This results in a change in cross-sectional area of the gauge which
causes a change in resistance to an electric current. Therefore, the gauge
is able to accurately determine the strain on a structure using the
relationship between strain in the structure and resistance in the flow of
current through the strain gauge.
If the dimensions and the applied forces of a cantilever are known, the
following equations can be used to calculate the stress at the top surface
of the beam resulting from vertical force (these calculated values for
varying loads can then be compared to experimental values to
demonstrate the accuracy of the strain gauge):

Figure 1: Cantilever beam arrangement (Courtesy - UOW)

Calibrating a strain gauge involves the application of varying loads to a

structure and recording the observed strain gauge output. The
relationship between load and strain can then be plotted using the
experimental values and a calibration equation derived. An unknown load
could then be determined by experimentally determining the strain
experienced due to the load and using the calibration equation to
calculate the corresponding force.
Procedure:
Part 1: Cantilever Beam
- Measure the cantilever beam dimensions L, B and h and use these
values to calculate the theoretical stress and strain values for
varying load (0kg-10kg)
- Fix the strain gauge to the cantilever beam as instructed
- Take a zero reading with just the hanger as load
- Apply increasing load to the beam by placing weights on the hanger
(0kg-10kg) starting with zero load and record the strain gauge
output for each load.
- Starting with the 10kg load record
Cantilever Beam
the strain gauge output for
Dimensions
decreasing load (10kg-0kg)
L(mm)
202
- Compare the experimental strain
B(mm)
48
to the theoretically calculated
values.
h(mm)
5mm
- Apply the unknown
I(mm^4)
395.8
- mass hanger and record the
3
strain gauge reading (in mV and
strain)
- Plot the Load vs strain gauge output (kg vs V) and fit a straight line
to the data. Determine the calibration equation of this line and
therefore estimate the unknown mass.
Part 2: Vehicle Suspension System
- Change the connections so that the vehicle suspension system
strain gauges are attached to the data acquisition system. Apply the
load/s nominated by the tutor to the vehicle suspension and record
the results for each of the suspension components.
- Use tube dimensions and strain values to estimate the forces in the
suspension component
Results:
Part 1:

Calculations for One Data Point (Load=1kg):

Using =6*F*L/B*h^2
= (6*(1kg*9.81m/s^2)*202mm)/(48mm*(5mm)^2)
= 9.9081MPa
Using = /E where E(Cantilever)=240Gpa
= 9.9081MPa/240000MPa
= 0.0000412
Load (kg) Strain Gauge Load(N)
Strain Gauge
Calculated Calculated
Output
Output
Stress
strain ()
(MPa)
Ascending ()
Descending ()
Part 2:
0
0
0
0
0
1
0.000041
0.000042
9.9081
0.00004120
Tension or 19.8162
Tube Dimensions
Calculat
2 Forces in0.000082 Strain ()
0.000079
0.00008256
Suspension
Compressi 29.7248
ed Force
3
0.000120
0.000121
0.00012384
Components
on
(N)
4
0.000157
0.000158
39.6324
0.00016500
Zero
After
Outer
Inner
5
0.000201
0.000198
49.5405
0.00020640
Value
Load
Diamet
Diamet
6
0.000240
0.000238
59.4486
0.00024760
er
er
7
0.000278
0.000279
69.3567
0.00028896
(mm)
(mm)
8
0.000316
0.000317
79.2648
0.00033024
Pull
Rod
0
0.00016
Tension
12.7
10.9
98.937
9
0.000357
0.000356
89.1729
0.00037152
2
10
0.000400
0.000356
99.0810
0.00041280
Upper Forward A0
Compressi
15.8
14.0
-18.932
Unkno
0.000487
0.000488
Arm
0.00003
on
wn
1
Applied Load Type
Upper Rear A0
Compressi
15.8
14.0
-33.059
Vertical
20*3.37=67.4
661.194
Arm
0.00013
on
Side
10/5=2
19.62
6
Longitudinal
10/3=3.33
32.7
Lower Forward A0
Compressi
15.8
14.0
-29.926
Arm
0.00004
on
9
Lower Rear A- Arm
0
Compressi
15.8
14.0
-72.066
0.00011
on
8
Steering Arm
0
Compressi
12.7
10.9
-3.664
0.00000
on
6
1. Force in Suspension Components Calculations:
Load
(kg)

Using: F=*E*A (A=outer area-inner area)

F (Pull Rod)
F=0.000162*240GPa*(pi*((12.7mm-10.9mm)/2)^2)
F=98.937N
F(Upper Forward A-Arm)

F=-0.000031*240GPa*(pi*((15.8mm-14.0mm)/2)^2)
F=-18.932N
F(Upper Read A- Arm)
F=-0.000136*240GPa*(pi*((15.8mm-14.0mm)/2)^2)
F=-33.059N
F(Lower Forward A- Arm)
F=-0.000049*240GPa*(pi*((15.8mm-14.0mm)/2)^2)
F=-29.926N
F(Lower Rear A- Arm)
F=-0.000118*240GPa*(pi*((15.8mm-14.0mm)/2)^2)
F=-72.066N
F(Steering Arm)
F=-0.000006*240GPa*(pi*((12.7mm-10.9mm)/2)^2)
F=-3.664N
Strain Gauge Exp - Calculations and analysis

Load vs. Strain

12
f(x) = 25302.95x - 0.03

10
8

Load (kg)

6
4
2
0

Strain (V)

2.
Equation of trend line in terms of load:
y+ 0.0284
In terms of strain: x=
25303

y=25303 x0.0284

3. As expected there is a linear relationship between the applied load and

the strain measured.
load=253030.00048750.0284
4.
12.307 kg
6. The values acquired for the forces in the suspension system are
reasonable due to the way in which they were loaded. The weights were
not simply loaded directly onto each component; they were loaded in such
a way that the force was increased or decreased by a pivot. This increased
the vertical load by ~3.37, and decreased the side and longitudinal loads
by a factor of 5 and 3 respectively. The calibration of strain gauges on
suspension components is feasible, however, as they are directional, and

the strain isnt the same around the perimeter of the component, its
positioning is important.
7. Sources of error in the experiment include; inability to stop the mass
from swinging completely in part 1 resulting in fluctuating strain readings,
and in part 2, friction on the pivot point, however this is only minor.
Additionally, in part 2, the positioning of the strain gauges is important, as
strain around the perimeter of the component can vary more in one
location for a particular directions loading and could be a considerable
source of error. For both, the masses used may have had some variation
from their recorded mass, though this also should only be minor.
Discussion:

Looking at the data collected for part one and two we can identify
that increasing the load applied to a cantilever beam increases the
strain is affected, we can call this a linear relationship. Depending
on the direction in which this load is applied on the beam we can
identify whether the load causes a tensile strain or a compressive
strain.
In engineering, we always have to account for errors and try to
eliminate them as much as we can, but this almost impossible to do.
In this experiment even though we are using software and electronic
systems to tell us about the strain. This value can be affected by the
internal resistances in the electrical wires and the other
components. One other possible error could occur from using a very
old strain gauge that has lost its elasticity over the years of use.
Best ways to eliminate these errors are to do regular system checks
and calibrate the system properly. Some errors, such as human error
can be eliminated by training the instrument handler thoroughly.
During the experiment, the other student members who were
waiting for their chance to do the experiment were leaning on the
cars chassis, which could have affected the data collected. Also
cant forget to mention the human error involved in reading the
average value from the software user interface as the value runs
very quickly between max and a min set of values.
The length measurements were recorded to 0.1mm precision and
the strains measure from the strain gauge were measured with a
precision of 0.000001.
The strain measurements are very reliable as the order of accuracy
in which the data is recorded is very precise and accurate.

Conclusion:
During this experiment we gained the experience of using a strain gauge
and understanding how it works and its capabilities. This experiment
shows how the strains are change when loads are applied on a structure.
Using the data collected from the strain gauge, we were able to cross
check it with the strain values we calculated to see how accurate the
strain gauge measurements are to theoretical values. We also learnt how

to calibrate a strain gauge by varying the load applied. Overall this

experiment highlighted the use of strain gauge and how accurate it is to
theory learnt in the class.