Objective

1. To apply the strain gauge to obtain stress-strain curves.

2. To identify and determine the mechanical properties of any given metal alloy materials
by carrying out a series of uni-axial tension-compression tests.

Introduction

Metal alloys are widely used in various industries due to their desirable mechanical properties,
such as strength, toughness, and ductility. Identifying the composition of metal alloys is
important for ensuring the quality and performance of the end product. One method for
identifying the metal alloy is by analysing its stress-strain behaviour under uni-axial tension-
compression tests. The stress-strain curve can provide valuable information about the
mechanical properties of the material, including the Young’s Modulus, elastic limit,
proportional limit, yield point, yield strength, and compressive strength. Strain gauges are
sensors that can be attached to the surface of the material to measure the deformation or strain
it undergoes under load. This approach can be a useful tool for quality control and material
identification in various industries.

Equipment and Materials

Quantity estimation
Item Description *Item category (e.g., per set/group of
students)
Universal testing machine E 1
Strain gauge E 1
Strain gauge decoder E 1
Compression test specimen SP 1
Computer E 1

*Item category
SP Sample or specimen
C Consumable
CH Chemical
W Labware, glassware, tool, and
components
E Equipment
S Software
Experimental Procedures

Preparation

1. The unknown materials of test specimens (metal alloy cylindrical pieces) were collected
and put each one (one-by-one) on the Universal Testing Machine with a rigid spacer.
The specimen is positioned so that it will sit right at the center of the pressure plates to
avoid eccentricity of force when carrying out the experiment.
2. The strain gauge was being attached on the test specimen.
3. The cross head of the machine was being operated to slowly move, so that the pressure
plates touch each other to completely close the gap while observing the indicator where
force value shows 0kN.
4. The PC was being connected with the data logger DBU-120A unit through the USB
cable.
5. The data logger was observed to ensure the green LEDs is lit for ‘POWER’ and
‘MASTER’ which indicates the connection is ready.
6. The two wired leads of the strain gauge were being connected to terminal 1 and 3 of
the DBU-120A unit, respectively.

Data logger setting

1. From the Windows menu “Start” –> “All Programs” –> “DBU-120A”, the mouse
cursor was being moved to select “measurement”. The hardware communication was
then be initiated by the application program.
2. The green ID lamp was being ensured to lit to show below the section “DB0”.
3. The ‘Save Condition File’ was being selected and saved under your group’s own folder.
The ‘ok’ is being clicked to save the file.
4. The ‘Set Recording Data File’ was selected and the filename of the group name was
saved. The ‘ok’ was clicked.
5. The ‘The Balance’ icon was selected and the ‘ok’ was then clicked. Subsequently, the
‘ok’ was clicked on the following pop-up window messages.
6. The graph setting was being check and set to ‘Y-time 1 Graph’ (Located beside the
‘Set Recording Data File’). The ‘Change Display’ icon was then being clicked.
7. The ‘X-axis’ and ‘Y-axis’ icons on the bottom right were selected.
8. The ‘Sampling Frequency’ was being ensured to be set to 100 Hz and the ‘Number of
Data’ to be 500. The ‘Meas Mode’ was ensured to have set to ‘manual’.
Experiment
1. The following was double-checked.
a. The test specimen was properly inserted between the pressure plates of the
compression tester.
b. The strain gauge was ensured to be properly attached and its wire was not
tangled with any parts of the universal testing machine.
c. The strop of strain gauge was ensured to be properly attached to the test
specimen.
2. The ‘Monitor’ icon was pressed to begin the test. It has taken few seconds to online.
3. The ‘Rec’ button on the control panel was being pressed once the status line (at the
bottom portion of the window) shows ‘monitoring’.
4. The specimen was observed to ensure it does not get too close because fracture of the
specimen liberates all stored energy in the specimen.

Results
1. To obtain results, from the Window’s menu ‘Start’ – ‘All Programs’ - ‘DBU-120A’,
the ‘Reproducing Data’ was selected and clicked to start up the application for
reproduction of your stored data.
2. The data file was being selected and the ‘Read Data File’ button was being clicked.
3. One of your data files saved previously was being selected to reproduce and the
‘Open’ was clicked.
4. The ‘1-Graph Disp’ icon was selected.
5. The ‘X-axis’ and ‘Y-axis’ icons on the bottom right were selected. Both icons are
being ensured to be immersed.
6. The ‘Convert into the CSV Format’ button was selected for data saving. The data
will be saved as ASCII format which is compatible to Excel. The files have been
named appropriately for clear indication of the test.
7. The graph was plotted accordingly.
8. The type of metal alloy used in this experiment was being identified based on the
results
Results

Force (kN) Strain (μm/m) Stress (MPa)

-4.95 65 7.00
-9.5 170 13.44
-14.2 295 20.09
-18.7 420 26.46
-22.8 540 32.26
-26 635 36.78

Graph

Elastic Modulus

The elastic modulus of the experimental specimen is 51.8GPa. The predicted material for the
specimen above is Aluminium with elastic modulus of 70GPa.
Sample Calculations

𝐹
Engineering Stress, 𝜎 =
𝐴

Original Diameter, 𝐷 = 30 𝑚𝑚

𝐷 2
Surface Area, 𝐴 = 𝜋 ( )
2

30 𝑚𝑚 2
= 𝜋( )
2

= 706.85 𝑚𝑚2

Force Compressive Stress

-4.95kN 4950 𝑁
𝜎= = 7 𝑀𝑃𝑎
706.85 𝑚𝑚2
-9.5kN 9500 𝑁
𝜎 = = 13.44 𝑀𝑃𝑎
706.85 𝑚𝑚2
-14.2kN 14200 𝑁
𝜎 = = 20.09 𝑀𝑃𝑎
706.85 𝑚𝑚2
-18.7kN 18700 𝑁
𝜎 = = 26.46 𝑀𝑃𝑎
706.85 𝑚𝑚2
-22.8kN 22800 𝑁
𝜎 = = 32.26 𝑀𝑃𝑎
706.85 𝑚𝑚2
-26kN 26000 𝑁
𝜎 = = 36.78 𝑀𝑃𝑎
706.85 𝑚𝑚2

Percentage Error

Predicted Experimental Elastic Theoretical Elastic Percentage error

Specimen Modulus Modulus
Aluminium 51.8GPa 70GPa |51.8 − 70|
× 100%
70
= 26%
Discussion

A strain gauge is a sensor to measure the strain or deformation of an object. It works on the
principle of the piezoresistive effect, which is the change in electrical resistance of a material
in response to an applied mechanical strain. A typical strain gauge consists of a thin wire or a
thin film of a conducting material, such as a metal or a semiconductor, attached to a flexible
backing material. When the object to which the strain gauge is attached is subjected to a strain,
the gauge experiences a change in length, which causes the wire or film to undergo a change
in length. This change in length will cause the electrical resistance to change as well. The ratio
of change in resistance is directly proportional to the ratio of change in length.

∆𝑅 ∆𝐿 ∆𝑅 ∆𝐿
𝛼 → =𝑘
𝑅0 𝐿0 𝑅0 𝐿0

∆𝐿
Where R = resistance, L = length, and = strain
𝐿0

The alteration in the resistance of the wire or film is proportionate to the strain on the object
and can be measured by linking the gauge to a Wheatstone bridge circuit. The Wheatstone
bridge circuit consists of four resistors, with the strain gauge connected to one of them. When
a voltage is applied to the circuit, the change in resistance of the strain gauge induces an
imbalance in the bridge circuit, which can be measured as a change in voltage output.

Based on the obtained results, there is a direct correlation between the stress on the
specimen and the applied force. This relationship follows a simple engineering stress equation:
𝐹
𝜎 = , which shows a linear relationship between stress, σ, and force, F, as long as the surface
𝐴

area, A, remains constant. Moreover, when the specimen undergoes compression, the amount
of strain it produces also increases, in proportion to the amount of force. It is due to the formula
below.

∆𝐿
𝜀=
𝐿0

Where ∆𝐿 = change in length, and 𝐿0 = original length

This relationship is described by Hooke's law, which states that the strain within the elastic
limit of the material is directly proportional to the applied force. However, it is important that
there is a limit to this relationship. At a certain point, the material will no longer be able to
return to its original shape after the force is removed. This is known as the yield point, and any
further increase in force beyond this point can result in permanent damage or plastic
deformation of the material.

After plotting the stress-strain curve, the elastic modulus obtained from this specimen
is 51.8GPa. Therefore, the most logical material for this specimen will be Aluminium as the
identification is done based on the closest material in term of theoretical elastic modulus. The
percentage error for this specimen is 26%. This percentage error may be cause by the internal
or external factor. Firstly, the theoretical elastic modulus is calculated based on the properties
of the material being tested, such as its density, Young's modulus, and Poisson's ratio. However,
the actual material properties of the specimen used in the experiment may differ from the
assumed values used in the theoretical calculation. This can be due to variations in the
manufacturing process, composition, or other factors. Then, the theoretical elastic modulus
assumes ideal testing conditions, such as uniform loading, no slippage, and no deformation of
the testing equipment. However, in practical, it is difficult to achieve ideal testing conditions,
and variations in the testing conditions can lead to differences between the experimental and
theoretical results. After that, external factor such as the placement of the strain gauge on the
surface of the material can also affect the accuracy of the measurements. The gauge needs to
be placed in a location where the strain is representative of the overall deformation of the
material. If the gauge is placed in an area that experiences uneven strain, it can lead to errors
in the measurements.

To improve the accuracy of the experimental results, proper installation and calibration
of the strain gauges is crucial for accurate measurement of strain. After that, sources of noise
in the data acquisition system, such as electrical interference or thermal noise, can affect the
accuracy of the measurements. Furthermore, it is important to verify that the specimens are
properly aligned within the machine and that the pressure plates are parallel to the flat surface
of the specimens.
Conclusion

A strain gauge is a type of sensor that undergoes a change in electrical resistance when
subjected to a force, pressure, tension, weight, or other applied loads. By measuring this change
in resistance, it is possible to convert the applied load into a measurable electrical signal. When
used in conjunction with a universal testing machine, which applies stress to the material, it is
possible to generate a stress-strain curve that represents the mechanical properties of the test
material. From the results, the specimen has an elastic modulus of 51.8GPa and the material
with the nearest elastic modulus is Aluminium which has an elastic modulus of 70GPa. The
percentage error obtained in this experiment is 26% that might be due to the variations in the
manufacturing process, composition, or other factors. Other than that, the ideal condition, and
placement of strain gauge on the specimen will also affect the accuracy of the results. By
analysing the unique stress-strain behaviour of different alloys, it is possible to differentiate
between materials and accurately determine their elastic modulus. While there may be some
sources of error in the experimental setup and data analysis, these can be minimized through
careful calibration and measurement techniques. With further research and refinement, the
application of strain gauges in material testing may spread in a wide range of industrial and
scientific applications.