MT&QC Lab Manual

ARYABHARATHI POLYTECHNIC, TUMKUR.
M T & Q C LAB
What is Mechanical Testing of Materials and Quality Control?
Materials testing: measurement of the characteristics and behaviour of such substances as

metals, ceramics, or plastics under various conditions. The data thus obtained can be used in
specifying the suitability of materials for various applications—e.g., building or aircraft construction,
machinery, or packaging. A full- or small-scale model of a proposed machine or structure may be
tested. Alternatively, investigators may construct mathematical models that utilize known material
characteristics and behaviour to predict capabilities of the structure.
Materials testing breaks down into five major categories: mechanical testing; testing for
thermal properties; testing for electrical properties; testing for resistance to corrosion, radiation, and
biological deterioration; and non-destructive testing. Standard test methods have been established by
such national and international bodies as the International Organization for Standardization (ISO),
with headquarters in Geneva, and the American Society for Testing and Materials (ASTM),
Philadelphia.
Quality control (QC): is a procedure or set of procedures intended to ensure that a

manufactured product or performed service adheres to a defined set of quality criteria or meets the
requirements of the client or customer.
Necessity of material testing & quality control:
Materials’ testing is often the last step in the manufacturing process. Yet, quality is the result of both
the process and the material. If the material that goes into the product is defective, then the product
may be defective. Quality cannot be put in after the fact. In forming materials, understanding the
material’s properties can help to better predict the manufacturing outcome.
DEPARTMENT OF MECHANICAL ENGINEERING

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ARYABHARATHI POLYTECHNIC, TUMKUR. M T & Q C LAB
Experiment No. – 01
Thurston oil tester
Aim: To determine the coefficient of friction of the given lubricant oil by various loads and speeds.
Materials and apparatus: Thurston oil tester, Specimen oil, Thermometer, Tachometer, etc.
Theory: The Thurston oil tester is equipment used for determine the coefficient of friction
experimentally that is exist between two meeting surface in pressure of lubricating oil applied over the
surface. The coefficient of friction depends on the type of lubricant. It consists of bush bearing and the
shaft is driven by motor. The angle by which the pendulum swings, found out the coefficient of friction.
Procedure:
1. The pendulum is removed from the apparatus shafts are cleaned from oil and dust.
2. Fresh specimen oil is applied on the shaft bearing.
3. The shaft is fixed on the bearing & the equipment. Experiment is explained in two ways. They
are a) by keeping load constant and varying speed. & b) by keeping speed constant & varying
load.
4. The speed is fixed by changing, belt position & load is varied.
5. The angle deflected the shaft pendulum which is noted in degrees & converted in to radians.
6. The above procedure is repeated for different speed by changing the belt position.
7. The coefficient of friction is calculated by using the formula.
Tabular column: (for constant speed)
Sl. Spring load Speed in Temp. in Deflection K

K = CSinθ μ=
No. ‘P’ in Kg RPM 0
C P
degrees Radians

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Tabular column: (for constant load)
Sl. Spring load Speed in Temp. in Deflection K

K = CSinθ μ=
No. ‘P’ in Kg RPM 0
C P
degrees Radians
Calculations:
WR
 C=
r
Where: W = dead weight of the pendulum
R = swing length of the pendulum
r = radius of the shaft
 K = CSinθ
Where: C = Constant
θ = deflection in radius
K
 μ=
P
Where: P = Load in Kg
K = Load surface
μ = Coefficient of friction
Results & discussion:

1. The coefficient of friction of the given lubricating oil in constant load is found to
be___________
2. The coefficient of friction of the given lubricating oil in constant speed is found to
be___________

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Flash and fire point using Pensky martin’s (closed cup tester)
Aim: To determine the flash and fire point of the given oil using Pensky martin’s apparatus.
Materials and apparatus: Pensky martin apparatus, Thermometer, Heating unit, etc.
Theory: It is used to determine the flash point of the lubricating oils, fuel oils, solvents, solvent
containing material and suspension of solids.
It consists of three parts
a) Oil Cup which is made of Brass Material. Lid of the cup is provided with four openings of
standard sizes, first opening is for stirrer, second is for admission of air, third is for thermometer
and fourth is for introducing test flame
b) Shutter: At the top of the cup shutter is provided. By moving the shutter, opening in the lid opens
and flame is dipped in to this opening, bringing the flame over the oil surface. As the test flame is
introduced in the opening, it get extinguished, but when the test flame is returned to its original
position, it is automatically lightened by the pilot burner
c) Stove: It consists of 1. Air bath, 2. Top plate on which the flange of the cup rest.
Flash point is the lowest temperature at which the lubricating oil gives off enough vapors that
ignite for a moment when tiny flame is brought near it.
Fire point is the lowest temperature at which the vapors of the oil burn continuously for at least
five seconds when a tiny flame is brought near it.

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Procedure:
1. Clean and dry all the parts of the apparatus before the test is started.
2. Fill the cup with the given oil to be tested up to the level position.
3. Fix the thermometer in a vertical position.
4. Apply heat to the oil such that the temperature rise is from 50C to 60C per minute.
5. Apply the test flame for every degree rise of temperature. The first application of the test flame
should be at least 1000 C below expected value of the flash point. Stirring should be discontinued
during the application of flame.
6. Read and record the flash point temperature, as shown on the thermometer at the time of flame
application that causes a distinct flash in the surface of the cup, this the flash point of the oil.
7. Continue heating and stirring and the application of the flame at a particular temperature when the
flame persists for about 5 seconds then that temperature is free point of the oil.
8. Now take out the cup from the heating unit and cool gradually record flash and fire point
temperature, while cooling the cup.
9. Take the average of the flash point and fire point temperature.
Tabular column:
Flash point Fire point
Description of the oil
Increasing Decreasing Increasing Decreasing
temp. in 00 C temp. in 00 C temp. in 00 C temp. in 00 C
Results & discussion:

1. Average flash point of the given oil is found to be ________
2. Average fire point of the given oil is found to be _________

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Redwood viscometer
Aim: To determine the kinematic viscosity & absolute viscosity of the given oil using redwood
viscometer.
Materials and apparatus: Redwood viscometer, Weighing box, Thermometer, Stop watch, heating
source, etc.
Theory: Viscosity can be defined as the property of the fluid which offers resistance to the movement
of one layer of fluid over another adjacent layer of the fluid. The SI unit of the measurement of
viscosity of given fluid is N-S / m2.
Observations:
 Oil used = ___________
 Weight of the empty specific gravity bottle (W1) = ___________
 Volume of oil taken (V) = ___________
 Weight of bottle + collecting oil (W2) = ___________
 Density of given oil = ___________
Procedure:
1. The oil cup is clean using petrol and given oil is taken up to the mark.
2. The specific gravity bottle is cleaned and weighed accurately.
3. The room temperature is noted, the ball is lifted and the oil is collected in the specific gravity
bottle that is time taken for the flow of the oil is noted.
4. The specific gravity bottle with the oil is weighed accurately.
5. Repeat the experiment with the different temperature of the oil.
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Tabular column:
Weight of
Weight of
empty Time Absolut
specific Kinemati
Temp. specific for 50 Density e
Sl. gravity c
of oil gravity cc of oil in viscosity Mean
No. bottle with Viscosity
in 00 C bottle with ‘T’ in gm / cc in N-
oil ‘W2’ in in m2/sec
‘W1’ in Sec S/m2
grams
grams
Calculation:
W 2−W 1
 Density ρ = gm/cc
V
1.9
 Kinematic viscosity = [ 0.00246T – ] m2/ s
T
 Absolute viscosity = [Kinematic viscosity X Density ] N – S / m2
Results and discussion:

The viscosity of the given oil using redwood viscometer is found to be__________

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Say bolts viscometer
Aim: To determine the kinematic viscosity & absolute viscosity of the given oil at different temperature.
Materials and apparatus: Saybolt viscometer, 50 ml specific gravity bottle, Thermometer, Stop
watch, heating source, etc.
Theory: Viscosity can be defined as the property of the fluid which offers resistance to the movement
of one layer of fluid over another adjacent layer of the fluid. The SI unit of the measurement of
viscosity of given fluid is N-S / m2.
Observations:
 Oil used = ___________
 Weight of the empty specific gravity bottle (W1) = ___________
 Volume of oil taken (V) = ___________
 Weight of bottle + collecting oil (W2) = ___________
 Density of given oil = ___________
Procedure:
1. Clean the Saybolt viscometer using diesel or petrol.
2. Fix the cork at the orifice & fill the testing cup with oil whose viscosity is to be determined.
3. Place the 50cc specific gravity bottle in position under the orifice when the oil temperature
becomes steady at the desired value, remove the cork from the orifice & at the same time start
the stop watch.
4. Locate the specific gravity bottle, so that oil strikes the flared mouth and does not drop directly
in to the opening which would cause foaming.
5. When 50cc oil collects in the bottle. Stop the watch & note down the time taken and at the same
time fix the cork at the orifice.
6. Weight the bottle with oil & repeat the experiment at the different temperatures.(preferably an
increment of 100 C)

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Tabular column:
Time for 50 cc Weight of specific Density Kinematic Absolute
Sl. Temp. of
of oil ‘T’ in gravity bottle with in Viscosity viscosity in
No. oil in 00 C
Sec oil W2 in grams gm / cc in m2/sec N-S/m2
Calculation:
W 2−W 1
 Density ρ = gm/cc
V
1.9
 Kinematic viscosity = [ 0.00246T – ] m2/ s
T
 Absolute viscosity = [Kinematic viscosity X Density ] N – S / m2

1. The kinematic viscosity of the given oil in saybolt viscometer is found to be__________
2. The Absolute viscosity of the given oil in saybolt viscometer is found to be__________

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Impact test (Charpy)
Aim: To determine the Impact toughness (strain energy) through Charpy test.
Materials and Apparatus required: Impact testing machine, U notch is cut across the middle of one
face, etc.
Theory: In an impact test a specially prepared notched specimen is fractured by a single blow from a
heavy hammer and energy required being a measure of resistance to impact. Impact load is produced by
a swinging of an impact weight W (hammer) from a height h. Release of the weight from the height h
swings the weight through the arc of a circle, which strikes the specimen to fracture at the notch.
Observations:
 Length of the specimen = ____________________ mm
 Width of the specimen = _____________________ mm
 Breadth of the specimen below notch = _________ mm
 Area of the specimen below notch = ____________ mm2
Procedure:
1. Measure the dimensions of a specimen. Also, measure the dimensions of the notch.
2. Raise the hammer and noted own initial reading from the dial, which will be energy to be used
to fracture the specimen.
3. Place the specimen for test and see that it is placed center with respect to hammer. Check the
position of notch.
4. Release the hammer and note the final reading, Difference between the initial and final reading
will give the actual energy required to fracture the Specimen.
5. Repeat the test for specimens of other materials. Compute the energy of rupture of each
specimen.

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Tabular column:
Sl. Initial Energy Residual Energy Absorb Energy Impact strength
No. (E1) in joule (E2) in joule (E2-E1) in joule j/mm2
01
02
03
04
05
Calculations:
Impact energy
Impact strength = j/mm2
Effective cross sectional area below notch
Results and discussions: The average impact strength of the given specimen by Charpy test can be
found to be ___________ j / mm2

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Impact test (Izod)
Aim: To determine the Impact toughness or impact strength (strain energy) of given specimen in impact
testing apparatus (Izod test).
Materials and Apparatus required: Impact testing machine, Izod test specimen of mild steel, Vernier
caliper, Specimen setting fixture, etc.
Theory: In an impact test a specially prepared notched specimen is fractured by a single blow from a
heavy hammer and energy required being a measure of resistance to impact. Impact load is produced by
a swinging of an impact weight W (hammer) from a height h. Release of the weight from the height h
swings the weight through the arc of a circle, which strikes the specimen to fracture at the notch.
Observations:
 Length of the specimen = _____________________ mm
 Width of the specimen = ______________________ mm
 Breadth of the specimen below notch = __________ mm
 Area of the specimen below notch = _____________mm2
 Impact energy (as recorded on scale) = __________ j / mm2

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Procedure:
1. Measure the dimensions of a specimen. Also, measure the dimensions of the notch.
2. Lift the hammer to an appropriate knife edge position and notch the energy stored in the hammer.
3. Locate the test specimens on the machine supports,
4. Release the hammer. The hammer will break the piece and shoot up the other side of the specimen.
5. Note the residual energy indicated on the scale by the hammer.
6. Impact strength of the test specimen is the difference of the initial energy stored in hammer and the
residual energy.
Tabular column:
Sl. Initial Energy Residual Energy Absorb Energy Impact strength
No. (E1) in joule (E2) in joule (E2-E1) in joule j/mm2
01
02
03
04
05
Calculations:
Impact energy
Impact strength = j/mm2
Effective cross sectional area below notch
Results and discussions: The average impact strength of the given specimen in impact testing machine
(Izod test) can be found to be ___________ j / mm2

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Rockwell Hardness Test
Aim: To determine the hardness number of the given Specimen, using Rockwell hardness testing
machine.
Materials and Apparatus required: Rockwell hardness testing machine, Black diamond cone
indenter, a hardened steel ball of 1/16'' (1.587 mm), Hard Steel Specimen, etc.
Theory: Rockwell test is developed by the Wilson instrument co U.S.Ain1920. This test is an
indentation test used for smaller specimens and harder materials. The test is subject of IS: 1586. In this
test indenter is forced in to the surface of a test piece in two operations, measuring the permanent
increase in depth of an indentation from the depth increased from the depth reached under a datum
load due to an additional load. Measurement of indentation is made after removing the additional load.
Two types of Indenters are used in this test. A hardened steel ball of1/16'' (1.587 mm) diameter for
Rockwell B test and the diamond cone indenter having an angle of 120 degrees made of black
diamond, for Rockwell C test.
Observation:
 Take average of five values of indentation of each specimen. Obtain the hardness number from
the dial of a machine.
 Compare Brinell and Rockwell hardness tests obtained.

Precautions:
 Thickness of the specimen should not be less than 8 times the depth of indentation to avoid the
deformation to be extended to the opposite surface of a specimen.
 Indentation should not be made nearer to the edge of a specimen to avoid unnecessary
concentration of stresses. In such case distance from the edge to the center of indentation
should be greater than 2.5 times diameter of indentation.
 Rapid rate of applying load should be avoided. Load applied on the ball may rise a little
because of its sudden action. Also rapidly applied load will restrict plastic flow of a material,
which produces effect on size of indentation.
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Procedure:
1. Examine hardness testing machine.
2. Place the specimen on plat form of a machine. Using the elevating screw raise the platform and
bring the specimen just in contact with the ball. Apply an initial load until the small pointer
shows remark.
3. Release the operating valve to apply additional load. Immediately after the additional load
applied, bring back operating valve to its position.
4. Read the position of the pointer on the C scale, which gives the hardness number.
5. Repeat the procedure on the specimen selecting different points for indentations.
Tabular Column:
Sl.
No. Type of Type of Load Rockwell Hardness
Mean
Material Indenter (P) Number (RHN)
No.
01
02
03
04
05
Results and Discussion: The hardness number of the given Specimen, using Rockwell hardness
testing machine is found to be ________

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Brinell Hardness Test
Aim: To determine the hardness number of the given Specimen, using Brinell hardness testing machine.
Materials and Apparatus required: Brinell hardness testing machine, Black diamond cone indenter,
a hardened steel ball of 1/16'' (1.587 mm), Mild Steel Specimen, Aluminum Specimen, High – Carbon
Steel Specimen, etc.
Theory: Hardness of a material is generally defined as Resistance to the permanent indentation under
static and dynamic load. When a material is required to use under direct static or dynamic loads, only
indentation hardness test will be useful to find out resistance to indentation. The standard Brinell
hardness tester consists of an anvil for supporting the specimen, an elevating screw & arrangement for
raising or lowering the specimen level to the required height. The load application takes place through a
system of interconnected levers.
In Brinell hardness test, a steel ball of diameter (D) is forced under a load (P) on to a surface of
test specimen. Mean diameter (d) of indentation is measured after the removal of the load (P).
Observations & calculations:

 Take average of taken values so find indentation of each specimen. Obtain the hardness
2P
number from equation. BHN =
π D(D−√ D 2−d 2)
 Compare Brinell and Rockwell hardness tests obtained.
Procedure:
1. Select the load (P) and the Diameter (D) of the indenter according to the type of the material to
be tested.
2. Place the specimen on the anvil with its surface at perpendicular to the indenter.
3. Rise the anvil of the tester by means of the hand wheel until the specimen makes in contact
with ball.
4. Apply the load by means of hand lever.
5. Maintain the load of indenter for required time (say 15 to 20 Sec.).
6. Release the load & remove the specimen from the anvil.
7. Measure the diameter of the indentation using microscope.
8. Make the ‘N’ number of different independent hardness determinations on each specimen for
& calculate the BHN using the formula.
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Tabular Column:
Type of Dia of indentation

Type of Load
Sl. No. indenter BHN
material (P) d3(mm
(D) d1(mm) d2(mm)
)
01
02
03
04
05
Results and Discussion:

The hardness number of the given Specimen, using Brinell hardness testing machine is found to be
_________

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Tension Test
Aim: To determine the behavior of the given material under tensile load and to determine the following
 Young’s modulus
 Yield stress
 Ultimate stress
 Breaking stress
 Percentage stress
 Percentage reduction in Area
 Percentage elongation
Materials and Apparatus required: Mild steel, Aluminum, Universal testing machine, Dial Gauge,
Vernier caliper, Scale, etc.
Theory: The engineering tension test is widely used to provide basic design information on strength of
the materials. In the tension tests a specimen is subjected to continually increasing uni – axial tensile
force while simultaneous observations are made during elongation of the specimen. A Stress – Strain
curve is plotted for the load – elongation of the measurements.
Definitions:
Limit of proportionality: it is the limiting value of the stress up to which stress is proportional to
strain.
Elastic limit: this is the limiting value of stress up to which if the material is stressed and then
released (unloaded) strain disappears completely and the original length is regained.
Upper yield point: this is the stress at which, the load starts reducing and the extension increases.
This phenomenon is called yielding of material.
Lower yield point: at this stage the stress remains same but strain increases for some time.
Ultimate stress: this is the maximum stress the material can resist. At this stage cross sectional area at
particular section starts reducing very fast this is called neck formation.
Breaking point: the stress at which finally the specimen fails is called breaking point.
Hooks law: within the elastic limit, the stress proportional to the strain for an isentropic material.
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Observations:
 Initial Length of the specimen, l1 = _________mm.
 Initial diameter of the specimen, d1 = ________mm.
π d 12
 Original cross sectional area, A1 =
4
= ________mm2
 Breaking load (load at breaking point) Pb = __________ N.
 Ultimate load (max. load applied) Pu = __________ N.
 Final Length of the specimen, l2 = _________mm.
 Final diameter of the specimen, d2 = ________mm.
π d 22
 Final cross sectional area, A2 =
4
= _________ mm2
Calculations:
final length−initial length
 % Elongation = X 100
initial length
= ___________X 100
= _____________ %
initial area−final area

 % Reduction in area = X 100
initial area
(a ¿ ¿1−a2 )
= ¿ X 100
a1
= ________ %
pu
 Ultimate Tensile strength, = __________ N/mm2.
A1
pb
 Breaking strength, = __________ N/mm2.
A1
Load p
 Stress = σ= = __________ N/mm2.
Area A1
Change∈length δl
 Strain = e = = __________ N/mm2.
Orginal length l1
Stress σ
 Young’s Modulus, = E = = __________ N/mm2.
Strain e
Procedure:
1. The original dimensions of the specimen like original diameter, gauge length etc. is to be
measured.
2. The specimen is mounted on the UTM between fixed and movable jaws.
3. Load range in the machine is adjusted to its maximum capacity & appropriate position and
adjusted to zero.
4. For every 0.5 ton of load, the readings of dial gauge and extensometer are noted and tabulated.
5. The specimen is loaded continuously up to the ultimate load where there is formation of cup and
cone at neck in the specimen, which is to be noted.
6. With further loading the specimen breaks and breaking load is noted.

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7. The specimen is removed and final dimensions are measured.
Tabular column:
Sl. No. Load (P) Deflection (δ)

stress strain Young’s modulus
N/mm2 (x 10-3) N / mm2
Kg N microns X0.01(mm)
01
02
03
04
05
06
07
08
09
10
Graph: Stress V/S Strain

Following behavior values of the given material under compressive load is found to be _____

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Compression test
Aim: To determine the behavior of the given material under compressive load and to determine the
following
 Young’s modulus
 Modulus of elasticity
 Compressive strength
 Percentage decrease in length
 Percentage increase in Area

Materials and Apparatus required: Universal testing machine, Compression pads, Specimen, etc.
Theory: This is the test to know strength of a material under compression. Generally compression test is carried
out to know either simple compression characteristics of material or column action of structural member’s .It has
been observed that for varying height of member, keeping cross-sectional and the load applied constant, there is
an increased tendency towards bending of a member.
Observations:
 Material = _______
 Initial length l1 = _______ mm
 Initial diameter d1 = _____ mm
π d 12
 Initial or original cross section area A1 = ________ mm2
4
 Final length l2= ________ mm
 Final diameter d2 = _________ mm
π d 22
 Final cross sectional area A2 = ________ mm2
4
 Maximum load Pmax = _______ N
Calculations:
l1−l 2
 Percentage decrease in length = X 100 = ________
l1
A 2− A 1
 Percentage increase in area = X 100 = _________
A1
P max
 Compressive strength = N/mm2 ________
A1
P
 Stress = N/mm2 = __________
A

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change∈length
 Strain = = ______
original length
 Young’s modulus = stress / strain N/mm2( from graph)
Procedure:
1. The original dimensions of the specimen are measured and tabulated.
2. Specimen is mounted on the UTM between the fixed & movable jaws.
3. The load range in the machine is adjusted to its maximum.
4. The dial gauge is mounted on the machine at the appropriate positions.
5. The machine is switched on and the compressive load is applied gradually.
6. The loading is applied continuously until the specimen flattens.
7. The specimen is removed & final dimensions are measured.
Tabular column:
Stress
δl Young’s
Sl. No. Load Dial gauge reading N/mm Strain x 10-3
l1 modulus
2
mm(x0.01
Kg N micron
)
Graph stress v/s strain

Following behavior values of the given material under compressive load is found to be ______

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Bending test
Aim: To determine the behavior of the given material under bending and to determine the following.
 Modulus of elasticity
 Modulus of rupture

Materials and apparatus required: UTM, Specimen, Dial gauge, scale, etc.
Theory: Beams are subjected to bending moment and shearing forces which vary from section to
section. Bending moment at a section in a beam is the moment that is trying to bend it and is obtained
as the algebraic sum of the moments about the section of all the forces acting on the beam either to the
left or to the right of the section.
Observation:
 Material = _________
 Span length l = ________
 Breadth of the specimen b = ________
 Height of the specimen h = _________
 Cross sectional area at center = b x h = _______
 Load at fracture, pf = ________
Calculations:
b X h3
 Moment of inertia I = = ________
12
load P
 From the graph deflectio n = δ = ______
L3
 Young’s modulus E = = _________
48 I
 Maximum bending moment M = pf L / 4 = ________
M σb E
 Bending equation = =
I y R
M
 Bending stress σ b= ( )xY
I
 Y = h / 2 = _____

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3 Pf
 Modulus of rupture = = _______
2bh 2
Procedure:
1. Dimensions of the specimen are noted
2. The specimen is mounted on shackles and is fitted to the UTM
3. Dial gauge is mounted on the appropriate position and adjusted to read zero
4. The UTM is adjusted to have the suitable load range
5. The machine is switched on and bending load is applied gradually
6. The load is applied until the specimen breaks and the breaking load is noted.
Tabular column:
Load (P) Dial gauge deflection (δ) P
Sl. No.
δ
Kg N Micron mm ( X 0.01)
01
02
03
04
05
06
07
08
Graph: Load V/S Deflection

The behavior of the given specimen under bending are found to be ___________

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Shear Test
Aim: To determine the Ultimate shear strength of the given specimen using UTM and evaluate the
results.
Materials and Apparatus required: Universal testing machine, Shear Test Attachment, Vernier
Caliper, or Micrometer, Mild Steel Specimen, etc.
Theory: A shearing stress acts parallel to a plane, where as tensile & compressive stresses act normal
to the plane. There are 2 main types of Shear stress used in laboratory experiment. One is called direct
or transverse shear stress, & corresponds to the type of stress encountered in rivets, bolts & beams. The
other type of shear tress is called pure or Torsional shear stress encountered in shafts subjected to pure
torsion. Direct shear stress test are usually conduct to obtain a measure of shear strength & torsion tests
are usually employed to evaluate the basic shear property of a materials.
Observations & calculations:

 Material (i) Diameter of the specimen. d = _______
(ii) Length of the specimen. L = ________
π d2
 Cross sectional area of the specimen. A = _____mm2
4
P
 Ultimate shear strength of, τ = (Single shear)
A
= _______N/mm2
P
 Ultimate shear strength of, τ = (Double shear)
2A
= _______N/mm2

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Procedure:
 Length, breadth & average diameter of the Shear test Specimen are measured.
 Fix the specimen in the Shear Equipment for single shear & double shear separately.
 Keep the shear equipment on the fixed jaw of the UTM.
 Bring the indicator pointer on the measuring dial to zero.
 Apply the load slowly at right angles to the axis of the piece throughout the central block.
 Note the shear load at fracture.
Tabular Column:
Diamete Fracture Load Ultimate
Sl. Type of Type of Area
r N= Shear
No. Material Shear mm2 Kg
(d) mm Kg X 9.81 Strength
Single
01.
Double
02.
03.

The Ultimate shear strength of the given specimen is found to be _____________

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Page37
Vernier scale
Aim: To determine the linear dimension of the given specimen by using vernier caliper.
Materials and Apparatus required: Vernier caliper, Specimen, etc.
Theory: The principle of vernier is that when two scales or divisions slightly different in size are used,
the difference between them can be utilized to enhance the accuracy of measurement. The Vernier
Caliper essentially consists of two steel rules and these can slide along each other. The details are
shown in fig. below
1) Outside jaws: used to measure external diameter or width of an object

2) Inside jaws: used to measure internal diameter of an object
3) Depth probe: used to measure depths of an object or a hole
4) Main scale: gives measurements of up to one decimal place (in cm).
5) Main scale: gives measurements in fraction(in inch)
6) Vernier: gives measurements up to two decimal places(in cm)
7) Vernier: gives measurements in fraction (in inch)
Least count can be calculated as value of 1MSD / total no. of VSD. If 1 MSD = 0.1cm, total no.
VSD = 5 therefore LC = 0.02. Suppose 50 vernier scale I division coincide with 49 divisions on main
scale, and 1 MSD =1 mm. then 1 VSD = 49 / 50 of MSD = 49/50MM.and LC = 1-49/50= 0.02 mm.
Observations:
 Value of 1 Main scale division = __________ mm
 Total number of division on vernier scale = _______ div.
Value of 1 MSD
 Least count = = ___________ mm
Total No. of divisions on VS
Procedure:
1. Take the material (sample) for which the value must be measured & place that between a fixed
and movable jaw.
2. The whole movable jaw assembly is adjusted so that the two measuring tip just touch two parts
to be measured.
3. Then lock nut is tightened.
4. Final adjustment depending upon the sense of correct feel is made by the adjusting screw.
5. Measure the main scale readings i.e. the line coincide with o mark of vernier scale and noted
down the reading.
6. The measuring tip is so designed as to measure inside as well as outside dimension.

Page38
7. Calculate MSR, CVD (CVR) and TR (TSR).
Tabular column:
Sl. No. Type of material MSR CVD T R = MSR + (CVD X LC) Mean
01
02
03
04
05
The dimension of the given specimen by using vernier scale is found to be _______ mm.

Page39
Micrometer
Aim: To determine the linear dimension of the given specimen by using micrometer.
Materials and Apparatus required: Micrometer, Specimen, etc.
Theory: The micrometer essentially consists of U shaped frame. The end of the screw forms one
measuring tip and the other measuring tip is constituted by a stationary anvil in the base of the frame.
The screw is threaded for certain length and is plan afterwards. The plain portion is called sleeve and its
end is the measuring surface. The spindle is advanced by turning thimble connected to the spindle. The
spindle is aside fit over the barrel and barrel is the fixed part attached with frame. The barrel is
graduated in unit of 0.05cm.i.e.20division per cm, which is the lead of the screw for one complete
revolution. The thimble has got 25 divisions around its periphery on circular portion. Thus it sub-
divides each revolution of the screw in 25 equal parts i.e. each division corresponds to 0.002cm.
Observations:
 Zero Error = ___________div
 Zero Correction = ___________div
Distanceuncovered on pitch scale
 Pitch = screw head ¿ = ________________ mm
Number of rotations given ¿
pitch
 Least count = = ______________________ mm
Number of ÷on head scale
Procedure:
1. Take sample piece and slowly move the screw in clockwise direction and lock the nut.
2. Now measure the circular part and line coinciding with the scale.
3. Calculate PSR, HSR and TR. Take down the reading and follow the same.

Page40
Tabular column:
TR=PSR+(HSR±ZC)LC in
Sl. No. Type of material PSR HSR Mean
mm
01
02
03
04
05

The dimension of the given specimen by using micrometer is found to be _______ mm.

Page41
Vernier Height Gauge
Aim: To determine the linear dimension of the given specimen by using vernier height gauge.
Materials and Apparatus required: Vernier height gauge, Specimen, etc.
Theory: This is just as vernier caliper, equipped with special base block and other attachment which
make the instrument suitable for height measurements. Along with the sliding jaw assembly,
arrangement is provided to carry a removable clamp. The upper and lower surfaces of the measuring
jaws are parallel to the base, so that it can be used for measurements over or under surface. The vernier
height gauge is mainly used in the inspection of parts and work. With a scribing attachment in place of
measuring jaw, this can be used to scribe lines at certain distance above the surface. For all these
measurement, use of surface plate as datum surface is very essential.
Observations:
 Value of 1 Main scale division = __________ mm.
 Total number of division on vernier scale = __________ div.
Value of 1 MSD
 Least count = = ___________ mm.
Total No. of divisions on VS
Procedure:
1. Take the material (sample) for which the value must be measured.
2. Check the vernier and main scale must coincide at zero.
3. After checking the 0 mark, put the sample piece and slowly leaves the measuring jaw over the
piece.
4. Tight the screw and measure the main scale also vernier scale reading.
5. The line coincide with the main scale that the VSR and note down the MSR & CVD reading.
6. Calculate the total reading.
Page42
Tabular column:
01
02
03
04
05

The dimension of the given specimen by using vernier height gauge is found to be _______ mm.

Page43
Vernier Depth Gauge
Aim: To determine the linear dimension of the given specimen by using vernier depth gauge.
Materials and Apparatus required: Vernier depth gauge, Specimen, etc.
Theory: This is similar to vernier height gauge consists of main scale, vernier scale, jaws, and lock nut
fine adjustment screw like vernier caliper as shown in fig. In vernier depth gauge, graduated scale can
slide through the base and vernier scale remains fixed. The vernier scale is fixed to the main body of
the depth gauge and is read in the same way as vernier caliper. In vernier depth gauge, graduated scale
can slide through the base and vernier scale remains fixed. The main scale provides the datum surface
from which the measurements are taken. Vernier depth gauge is used to measure depth of holes,
distance from a plane surface to a projection and recess.
Observations:
 Value of 1 Main scale division = __________ mm
 Total number of division on vernier scale = __________ div.
Value of 1 Main Scale Division

 Least count = = ___________ mm
Total No. of divisions on Vernier Scale
Procedure:
1. Take the material (sample) for which the value must be measured & place that between a base
and a jaw.
2. Note down the line coincides with the MSR & CVD reading.
3. Calculate the total reading using equation.

Page44
Tabular column:
01
02
03
04
05

The dimension of the given specimen by using vernier depth gauge is found to be _______ mm.

Page45
Measurement of Taper Using Bevel Protractor
Aim: To determine the Taper angle of the given specimen by using Bevel Protractor.
Materials and Apparatus required: Surface plate, Bevel protractor, Tapered work piece, etc.
Theory: It is the simplest instrument used for measuring and laying out of angles accurately and
precisely within 5 minutes. It consists of base plate attached to the main body and a adjustable blade
which is attached to a circular plate containing vernier scale. The adjustable blade is capable of rotating
freely about center of the main scale engraved on the body of the instrument and can be locked in the
any position. It is capable of measuring from zero to 3600.
Observations:
 Initial error in the Bevel Protractor _____________ min.
 Value of 1 Main scale division _________________ min.
 No. of divisions on Vernier scale _______________
Value of 1 Main scale division
 Least count =
No . of divisions on Verinier scale
10
L.C. =
12
601
L.C. =
12
L.C. = 51
Procedure:
1. Note down the least count of the bevel protractor.
2. Keep the work piece on the surface plate.
3. Fix the slide of the bevel protractor to the turret.
4. Keep one of the surface of the specimen on the working edge and rotate the turret. Remove the
slid on to the other surface.
Page46
5. Fix the center, after matching the both faces and note down the reading.
Tabular column:
Sl. Main scale Coincide vernier Angles
Specimen
No. Reading (MSR) division (CVD) [TAR = MSR + (CVD X LC)]
01
02
03
04
05
Calculations:
1) Total angular reading (TAR) = [MSR + (CVD X LC)]
Results & Discussion:

Taper angle of the given specimen by using Bevel Protractor is found to be _________

Page47
Measurement of gear tooth vernier caliper
Aim: To determine the tooth thickness and other parameters of a gear by using gear tooth vernier
caliper.
Materials and Apparatus required: Gear tooth vernier caliper, Vernier caliper, Spur gear preferably
50 mm to 75 mm diameter, etc.
Theory: The measurement of spur gear element depend on the geometrical principle of the involutes
gear that the distance between parallel between lines embracing several teeth is constant and is equal to
the arc on the base circle interested by the extreme points. The principle will naturally be strictly true
only for a gear, which is perfect on tooth from, pitch concentricity etc. therefore select precision gear,
preferably ground and known to have only small errors in these elements. In measurements of gear
tooth the following elements are checked.
1) Pitch circle diameter: it is the diameter of the pitch circle which by pure rolling action would
produce the same motion as the toothed gear. Size of the gear is usually specified by pitch circle
diameter.
2) Module: it is the ratio of the pitch circle diameter in millimeter to the number of teeth or it is the
length of the pitch circle diameter per tooth. It is usually denoted by ‘m’.
3) Addendum: it is the radial distance of the tooth from the pitch circle to the top or tip of the tooth.
4) Deddendum: it is the radial distance of the tooth from the pitch circle to the bottom of the tooth.
5) Tooth thickness: it is the width of the tooth measured along the pitch circle.
6) Blank diameter: this is the diameter of the blank from which gear is cut.

Page48
Observations:
 Least count of the gear tooth caliper ____________ mm

 Least count of the vernier caliper _______________ mm
 Initial error in the caliper ______________________ mm
 Number of teeth’s on the gear __________________ mm
Procedure:
1. Note down the least count of the gear tooth vernier caliper and vernier caliper.
2. Measure the diameter of gear blank using vernier caliper also count the number of teeth’s on the
gear blank.
3. Calculate the addendum .of the gear tooth and fix the same diameter in vertical vernier scale and
use the horizontal scale to measure the thickness of the gear tooth over the pitch line.
4. Measure the same parameters for different teeth’s.
5. Take the average of tooth thickness.
6. Calculate all the other parameters using the formulae.

Page49
Tabular column:
Sl. Tooth thickness measured Tooth thickness calculated
Difference
No. ‘mm’ ‘mm’
01
02
03
04
05
Calculation:
1) Diameter of gear blank, D = MSR + (VSR X LC) ± initial error in mm
2) Number of teeth’s on gear Z = _______
D
3) Module m = = __________________
Z
90
4) Theoretical thickness of tooth, Wt = Z X m X Sin( ¿ in mm
Z
m 2 90
5) Cordal Addendum da = Z X [1+ – Cos ( )] in mm
2 Z Z
6) Deddendum d = [ da + (0.175) m] in mm
7) Pitch circle diameter dp = [m X Z] in mm
8) Depth of teeth h = [da + d] in mm
9) Root diameter Dr = [D – 2h] in mm
Results & Discussion:

The tooth thickness and other parameters of a gear by using gear tooth vernier caliper are found to
be_______

Page50

Page51
Measurement of Taper Using Sine Bar
Aim: To determine the Taper angle of the given specimen by using Sine bar and compare it with
theoretical value by using sine bar.
Materials & apparatus required: Surface plate, Sine bar, Slip gauge sets, Tapered work piece, clean
dry soft cloth, cleaning agent & clamping devices, etc.
Theory: The angle is defined as the opening between the two lines or planes which meet at a point. So
angle is a thing which can be generated very easily requiring no absolute standard. Sine bars are used in
junction with slip gauges constitute a very good device for the precision measurement of angles. Since
sine bars are used either to measure angel very accurately or for locating any work to a given angle of
the object having flat surface. Sine bars are also used to measure or set angle of the object not longer
than 450, if higher accuracy is demanded. Sine bars are made from high carbon, high chromium
corrosion resistant steel, hardened ground and stabilized.
Observations:
 Least count of the Vernier caliper_______________________ mm

 Least count of dial gauge______________________________ mm
 Distance between the center of rollers of sine bar L = _______ mm

Page52
 Length of the specimen (axial length) l = ________________ mm

Procedure:
1. Set the sine bar on the surface plate.
2. Measure the distance between rollers of center of sine bar.
3. Mark the position of the rollers on the surface plate which is advantage if the position of the sine bar
is changed.
4. The axial length of the taper under test is noted by use of vernier caliper.
5. Tapered work piece is fixed on the surface of the sine bar by means of clamp and so positioned that
easily access whose length of the taper to the dial gauge.
6. The dial gauge is fixed on its stand which in turns is fixed on the slide way.
7. Note down the least count of the dial gauge used.
8. Adjust the slip gauge height on the taper to be measure in such a way that it easily takes slip on the
smaller end and note down dial gauge reading at the entry end.
9. By sliding the dial gauge across the work piece length take reading of the dial gauge on other end.
10. Calculate the approximate height of slip gauge required at smaller dimension end in order to make
upper surface of the work piece parallel to the reference plane.
11. Without altering the position of the roller place the slip gauge pile under the roller of small size end
of the sine bar set up
12. Then test with dial gauge for null deflection. If there is any slight deflection in dial gauge then alter
slip gauges pile until getting null deflection.
13. With the help of formulas given in, calculate the acute angle and theoretical angle of taper and error
in taper.
Tabular column:
specimen ‘l’ mmTaper length of
dial gauge ‘h1’Initial reading of
dial gauge ‘h2’Final reading of
Ht. of slip
Ht. of slip
Difference of dial
angle θtheTheoretical taper
θactactual taper angle

gauge reading
Errors
Sl. No.
reading
reading
gaugeActual
gaugeApp.
dh = (h2 – h1)
01
02
03
04
05

Page53
Calculations:
1) Initial reading of dial gauge h1 = ___________ mm
2) Final reading of dial gauge h2 = ___________ mm
3) Difference in dial gauge reading dh = (h2 – h1) = _______ mm
(dh X L)
4) Approximate height of slip gauge used Happ. =
√(dh2 +l2)
dh
( )
5) Theoretical taper angle θthe = tan – 1
l
= ________
H act
6) Actual taper angle θact = Sin – 1( ) = _____________
L
7) Error θact – θthe = _______

Taper angle of the given specimen by using Sine bar is found to be ________

Page54
Study Experiment
Surface Defects By Dye Penetrant Test
Dye penetrant Test also called liquid penetrant inspection (LPI) or penetrant

testing (PT), is a widely applied and low-cost inspection method used to locate surface-
breaking defects in all non-porous materials (metals, plastics, or ceramics). The
penetrant may be applied to all non-ferrous materials and ferrous materials, although for
ferrous components magnetic-particle inspection is often used instead for its subsurface
detection capability. LPI is used to detect casting, forging and welding surface defects
such as hairline cracks, surface porosity, leaks in new products, and fatigue cracks on in-
service components.
History
The oil and whiting method used in the railroad industry in the early 1900s was the first
recognized use of the principles of penetrants to detect cracks. The oil and whiting
method used an oil solvent for cleaning followed by the application of a whiting or chalk
coating, which absorbed oil from the cracks revealing their locations. Soon a dye was
added to the liquid. By the 1940s, fluorescent or visible dye was added to the oil used to
penetrate test objects.
Experience showed that temperature and soak time were important. This started the
practice of written instructions to provide standard, uniform results. The use of written
procedures has evolved, giving the ability for design engineers and manufacturers to get
the high standard results from any properly trained and certified liquid penetrant testing
technician.

Page55
Principles
DPI is based upon capillary action, where low surface tension fluid penetrates into clean
and dry surface-breaking discontinuities. Penetrant may be applied to the test component
by dipping, spraying, or brushing. After adequate penetration time has been allowed, the
excess penetrant is removed and a developer is applied. The developer helps to draw
penetrant out of the flaw so that an invisible indication becomes visible to the inspector.
Inspection is performed under ultraviolet or white light, depending on the type of dye
used - fluorescent or nonfluorescent (visible).
Inspection steps
Below are the main steps of Liquid Penetrant Inspection:
1. Pre-cleaning:
The test surface is cleaned to remove any dirt, paint, oil, grease or any loose scale that
could either keep penetrant out of a defect, or cause irrelevant or false indications.
Cleaning methods may include solvents, alkaline cleaning steps, vapor degreasing, or
media blasting. The end goal of this step is a clean surface where any defects present are
open to the surface, dry, and free of contamination. Note that if media blasting is used, it
may "work over" small discontinuities in the part, and an etching bath is recommended
as a post-blasting treatment.
Application of the penetrant to a part in a ventilated test area.
2. Application of Penetrant:
The penetrant is then applied to the surface of the item being tested. The penetrant is
allowed "dwell time" to soak into any flaws (generally 5 to 30 minutes). The dwell time
mainly depends upon the penetrant being used, material being tested and the size of
flaws sought. As expected, smaller flaws require a longer penetration time. Due to their
incompatible nature one must be careful not to apply solvent-based penetrant to a
surface which is to be inspected with a water-washable penetrant.

Page56
3. Excess Penetrant Removal:

The excess penetrant is then removed from the surface. The removal method is
controlled by the type of penetrant used. Water-washable, solvent-
removable, lipophilic post-emulsifiable, or hydrophilic post-emulsifiable are the
common choices. Emulsifiersrepresent the highest sensitivity level, and chemically
interact with the oily penetrant to make it removable with a water spray. When using
solvent remover and lint-free cloth it is important to not spray the solvent on the test
surface directly, because this can remove the penetrant from the flaws. If excess
penetrant is not properly removed, once the developer is applied, it may leave a
background in the developed area that can mask indications or defects. In addition, this
may also produce false indications severely hindering your ability to do a proper
inspection. Also, the removal of excessive penetrant is done towards one direction either
vertically or horizontally as the case may be.
4. Application of Developer:
After excess penetrant has been removed, a white developer is applied to the sample.
Several developer types are available, including: non-aqueous wet developer, dry
powder, water-suspendable, and water-soluble. Choice of developer is governed by
penetrant compatibility (one can't use water-soluble or -suspendable developer with
water-washable penetrant), and by inspection conditions. When using non-aqueous wet
developer (NAWD) or dry powder, the sample must be dried prior to application, while
soluble and suspendable developers are applied with the part still wet from the previous
step. NAWD is commercially available in aerosol spray cans, and may
employ acetone, isopropyl alcohol, or a propellant that is a combination of the two.
Developer should form a semi-transparent, even coating on the surface.
The developer draws penetrant from defects out onto the surface to form a visible
indication, commonly known as bleed-out. Any areas that bleed out can indicate the
location, orientation and possible types of defects on the surface. Interpreting the results
and characterizing defects from the indications found may require some training and/or
experience [the indication size is not the actual size of the defect].
5. Inspection:
The inspector will use visible light with adequate intensity (100 foot-candles or
1100 lux is typical) for visible dye penetrant. Ultraviolet (UV-A) radiation of adequate
intensity (1,000 micro-watts per centimeter squared is common), along with low
ambient light levels (less than 2 foot-candles) for fluorescent penetrant examinations.
Inspection of the test surface should take place after 10- to 30-minute development time,
depends of product kind. This time delay allows the blotting action to occur. The
inspector may observe the sample for indication formation when using visible dye. It is
also good practice to observe indications as they form because the characteristics of the
bleed out are a significant part of interpretation characterization of flaws.
Page57
6. Post Cleaning:
The test surface is often cleaned after inspection and recording of defects, especially if
post-inspection coating processes are scheduled.
Advantages and disadvantages
The main advantages of DPI are the speed of the test and the low cost. Disadvantages
include the detection of only surface flaws, skin irritation, and the inspection should be
on a smooth clean surface where excessive penetrant can be removed prior to being
developed. Conducting the test on rough surfaces, such-as "as-welded" welds, will make
it difficult to remove any excessive penetrant and could result in false indications.
Water-washable penetrant should be considered here if no other option is available.
Also, on certain surfaces a great enough color contrast cannot be achieved or the dye
will stain the workpiece.
Limited training is required for the operator — although experience is quite valuable.
Proper cleaning is necessary to assure that surface contaminants have been removed and
any defects present are clean and dry. Some cleaning methods have been shown to be
detrimental to test sensitivity, so acid etching to remove metal smearing and re-open the
defect may be necessary.

Page58

MT&QC Lab Manual

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ARYABHARATHI POLYTECHNIC, TUMKUR.

What is Mechanical Testing of Materials and Quality Control?

Materials testing: measurement of the characteristics and behaviour of such substances as

Quality control (QC): is a procedure or set of procedures intended to ensure that a

Necessity of material testing & quality control:

DEPARTMENT OF MECHANICAL ENGINEERING

Sl. Spring load Speed in Temp. in Deflection K

DEPARTMENT OF MECHANICAL ENGINEERING

Tabular column: (for constant load)

Sl. Spring load Speed in Temp. in Deflection K

Results & discussion:

DEPARTMENT OF MECHANICAL ENGINEERING

DEPARTMENT OF MECHANICAL ENGINEERING

DEPARTMENT OF MECHANICAL ENGINEERING

DEPARTMENT OF MECHANICAL ENGINEERING

Results & discussion:

DEPARTMENT OF MECHANICAL ENGINEERING

Results and discussion:

DEPARTMENT OF MECHANICAL ENGINEERING

DEPARTMENT OF MECHANICAL ENGINEERING

Results and discussion:

DEPARTMENT OF MECHANICAL ENGINEERING

DEPARTMENT OF MECHANICAL ENGINEERING

DEPARTMENT OF MECHANICAL ENGINEERING

DEPARTMENT OF MECHANICAL ENGINEERING

DEPARTMENT OF MECHANICAL ENGINEERING

DEPARTMENT OF MECHANICAL ENGINEERING

DEPARTMENT OF MECHANICAL ENGINEERING

DEPARTMENT OF MECHANICAL ENGINEERING

Observations & calculations:

Type of Dia of indentation

Results and Discussion:

DEPARTMENT OF MECHANICAL ENGINEERING

initial area−final area

DEPARTMENT OF MECHANICAL ENGINEERING

7. The specimen is removed and final dimensions are measured.

Sl. No. Load (P) Deflection (δ)

Graph: Stress V/S Strain

Results and Discussion:

DEPARTMENT OF MECHANICAL ENGINEERING

DEPARTMENT OF MECHANICAL ENGINEERING

DEPARTMENT OF MECHANICAL ENGINEERING

Graph stress v/s strain

Results and discussion:

DEPARTMENT OF MECHANICAL ENGINEERING

DEPARTMENT OF MECHANICAL ENGINEERING

DEPARTMENT OF MECHANICAL ENGINEERING

DEPARTMENT OF MECHANICAL ENGINEERING

Graph: Load V/S Deflection

DEPARTMENT OF MECHANICAL ENGINEERING

DEPARTMENT OF MECHANICAL ENGINEERING

DEPARTMENT OF MECHANICAL ENGINEERING

Observations & calculations:

(ii) Length of the specimen. L = ________

DEPARTMENT OF MECHANICAL ENGINEERING

Results and Discussion:

DEPARTMENT OF MECHANICAL ENGINEERING

DEPARTMENT OF MECHANICAL ENGINEERING

DEPARTMENT OF MECHANICAL ENGINEERING

Materials and Apparatus required: Vernier caliper, Specimen, etc.

1) Outside jaws: used to measure external diameter or width of an object

DEPARTMENT OF MECHANICAL ENGINEERING