MUHAMMAD FAIZ BIN SELAMAT KEM110036 ERS GAUGE CALIBRATION

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ABSTRACT
The experiment in electrical resistance strain gauge calibration is carried out using a set of apparatus.
A standard HSM 17 is successfully installed onto a steel beam with strain gauge attached. Different
strain value is tested from 200 to 1000 to the beam and ERS reading is taken. The deflection of
beam is created by applying forces from the bottom of the beam controlled by a hand wheel. In every
one complete rotation, 200 is created to the beam. After all the data needed is collected, errors,
negative and positive deviation are calculated, and then percentage of batch average factor can be
determined.


INTRODUCTION
Strain gauge basically is a device which is used to measure the strain of an object. It is invented by
Edward E. Simmons and Arthur C. Ruge around 1938. Modern strain gage instrument usually employ
the Wheatstone bridge as primary sensing circuit.
While there are several method to measure strain, the most common method is by using an electrical
device which resistance varies in proportion to the amount of strain. Basically it takes advantage of
physical property of electrical conductance, which really depends on conductor geometry. Commonly
used is conductive meta strip.
If a strip of conductive metal is stretched, it will become skinner and longer. Simply, the changes
resulted in an increase of electrical resistance. We can expect opposite result if conductive metal is
placed under compressive force, it will broaden and shorten. If the strip does not continuously deform,
it can be used as a measuring element for physical force (amount of applied force inferred from
measuring its resistance).

A strain gauge's conductor is very thin: if made of round wire, it is about 1/1000 inch in diameter.
Alternatively, strain gauge conductors may be thin strips of metallic film deposited on a non-
conducting substrate material called the carrier. The latter form of strain gauge is represented in the
previous illustration. The name "bonded gauge" is given to strain gauges that are glued to a larger
structure under stress (called the test specimen). The task of bonding strain gauges to test specimens
may appear to be very simple, but it is not. "Gauging" is a craft in its own right, absolutely essential
MUHAMMAD FAIZ BIN SELAMAT KEM110036 ERS GAUGE CALIBRATION

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for obtaining accurate, stable strain measurements. It is also possible to use an un-mounted gauge wire
stretched between two mechanical points to measure tension, but this technique has its limitations.

some errors which are commonly encountered when using strain gauges:
- Temperature coefficient of Gauge Factor (TCGF) change the sensitivity of the device
- Zero Offset related to the ERS circuit
- Zero Shift with temperature
- Linearity - an error whereby the sensitivity changes across the pressure range
- Humidity


Theory
The four point loadings system used provides a constant bending moment along the central
portion of the beam, which therefore has a constant radius of curvature. From the geometry of the
circle, the central deflection o from the chord over a fixed length L is derived from,
2
2 2
2
1
) (
|
.
|

\
|
+ = L R R o

And because of the high degree of accuracy required, o
2
is not negligible
|
.
|

\
|
+ =
2 2
4
1 1
2 o
o
L R
The structural theory involved is the theory of bending from which the surface strain on the beam is
given by

R
t
R
R t R
2
2
1
=

|
.
|

\
|

=
u
u u
c

t = depth of beam
R = radius of curvature of neutral axis

Hence,
|
.
|

\
|
+
=
2 2
4
1
o
o
c
L
t
-1

To investigate the required accuracy, the length L over which the curvature is measured is taken as an
example. Differentiating (1)
MUHAMMAD FAIZ BIN SELAMAT KEM110036 ERS GAUGE CALIBRATION

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dL
L
L t
d
2
2 2
4
1
2
|
.
|

\
|

=
o
o
c
-2
and dividing -2 by -1

L
dL
dL
L
L d 2
4
1
2
2 2

|
.
|

\
|

=
o
c
c

For an accuracy of 0.1% of strain the accuracy of L should be 0.05%. The tolerance on L shown in
DD6/72 is 0.1%.




OBJECTIVE
1. To study usage of structural theory to strain gauge calibration
2. To study accuracy and source of error in calibration
3. To introduce quality output control and measurement of material to student



EQUIPMENT
A self-contained four point loading system with inner reaction 310 mm apart and forced upward by
screw is used. All the reactions are applied through twin ball bearings in order to make endlong
restrain negligible the inner reaction are self-aligning to provide an even bearing. Then a high strength
ground steel beam is used to develop surface strain up until 1000 . A dial gauge is provided with
indicating ratio is set to read out directly in micro-strain for beam supplied with the apparatus.
Table 1 shows the detail of Gauge Factor Determination
Detail of ERS gauge E10MIC II
Manufacturer Hi-Tech Scientific
Type and size HSM 17
Batch average resistance 1.06
Batch average gauge factor 2.13

An Electronic Resistance Strain gauge is connected to the two active arms in abridge circuit of the
strain meter. After the apparatus is set up, the experiment is conducted carefully.

MUHAMMAD FAIZ BIN SELAMAT KEM110036 ERS GAUGE CALIBRATION

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PROCEDURE
i. The apparatus is set up accordingly to the manual
ii. The ERS gauge is switched on, then the handwheel under the loading frame is rotated slowly
until the dial response and shows an increment.
iii. Then, the ERS gauge and the strain meter dial is tarred to zero reading.
iv. The handwheel is rotated until the dial complete 1 rotation, in other words, 200 increment.
Then reading shown on ERS gauge is recorded.
v. The step is repeated for 200 increment to get 400, 600, 800, and 1000 .
vi. Then the handwheel is rotated in opposite direction to decrease the value to 800 . The
reading shown on ERS gauge is recorded.
vii. The step is also repeated gradually 200 , to get 600, 400, 200 and 0 . In other words,
reading is taken in reverse process.
viii. The procedure is repeated until 3 sets of data is achieved
ix. Average of strain is calculated
x. The deviation and batch average factor can be calculated.

RESULT
Detail of ERS gauge E10MIC II
Manufacturer Hi-Tech Scientific
Type and size HSM 17
Batch average resistance 1.06
Batch average gauge factor 2.13



Loading
Strain increment ( )
0 200 400 600 800 1000
Strain gauge meter readings
0 200 400 600 800 1000
Cycle direction Strain gauge meter readings
1
st
increasing 0 214 418 619 821 1031
Decreasing 10 195 396 598 800 1031
2
nd
increasing 0 233 400 617 814 1026
Decreasing 8 187 390 591 792 1026
3
rd
increasing 0 228 414 613 806 1022
Decreasing 7 189 406 605 805 1022
Average meter
reading
4 208 404 605 805 1026
Maximum
deviation from
average (+%)
140% 12%
3%
2% 2%
0.46%
(-%) 100% 10% 3% 2% 1.6% 0.42%
MUHAMMAD FAIZ BIN SELAMAT KEM110036 ERS GAUGE CALIBRATION

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Correction to batch average factor
= Gauge factor as set

= 2.13

= 2.14
Gauge error =

= 0.47% of error



DISCUSSION
The experiment was done with all the objective is achieved. The main objective is to determine a
new gauge factor and percentage of error, a comparison from the stated gauge factor. From the
experiment, calculation and value that I chose, the gauge factor I got is 2.14, which is 0.47%
differ from the value stated at the material during its production. Always, the will be some error in
carrying a lab experiment. The errors are determined and discussed together with my other lab
members.
Some of errors that is possible to happen are :-
- The possibility that the beam is not straight at the beginning. This will affect the zero
reading of the gauge
- Parallax error may occur. Eyes position incorrect when reading is taken. Besides, the
reading is taken by different observer, thus the interpretation should differ each other.
- The sensitivity of the strain gauge may not accurate as the tools are bit old. Also, many
experiments is carried before using the same tools.
- During the first attempt to give initial force using the hand wheel, the force may not
uniform for each reading (3 reading is taken in this case). Thus after the tarring, zero
values may not the same or every set of data.
- Some of environment factors also can affect like the surrounding temperature which can
affect the resistance.
There are steps can be taken as precaution to get more accurate result:
- 3 sets of data is taken to get the average o more accurate data can be achieve.
MUHAMMAD FAIZ BIN SELAMAT KEM110036 ERS GAUGE CALIBRATION

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- Gently rotate the hand wheel to ensure the applied forces is accurate with the strain
gauge.
- Any steps that can make the temperature constant like controlling the air conditioner.
For strain with accuracy in 0.5% acceptance limit:
1005
1000
100
5 . 0
1000
=
|
.
|

\
|
+ =
c
c

Substituting into formula:
Correction to batch average factor,
=Gauge factor as set x average meter reading
1000
14 . 2
1000
1005
13 . 2
=
=
new
new
GF
GF


Therefore, the new gauge factor which is capable to give strain with accuracy in 0.5%
acceptance limit is 2.14.

Based on structural theory:
R
t
R
R t R
2
2
1
=

|
.
|

\
|

=
u
u u
c

Thus, t is determined from
c = R t 2

|
.
|

\
|
+
=
2 2
4
1
o
o
c
L
t

0
4
1
2 2
= + L t c o co

Thus, the o can be determined by solving the quadratic equations.



There are also other errors that affecting the overall experiment such as:
- Zero error
- Parallax error
- Poor sensitivity on the strain gauge
- Surrounding temperature and conditions
- Extra load from the subject





MUHAMMAD FAIZ BIN SELAMAT KEM110036 ERS GAUGE CALIBRATION

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CONCLUSION

In conclusion after the experiment was done, the new gauge factor is calculated based on the data we
get, which is 2.14. It is about 0.47% differs from the given value on the beam. Hence the factors
stated above may be used as the experiment was carried out carefully but the result is differ with the
theoretical data.

REFERENCES
1. William F. Smith, Javad Hashemi. Foundations of Materials Science and Engineering (4
th

Ed). McGraw Hill.
2. H.B. Dale, B.Sc.(Eng.) (Hons.), A.M.I.Mech.E., A.M.I.Prod.E., (1960) "An Introduction to
Electrical Resistance Strain Gauges", Education + Training, Vol. 2 Iss: 6, pp.29 30
3. http://en.wikipedia.org/wiki/Strain_gauge
4. http://www.allaboutcircuits.com/vol_1/chpt_9/7.html