Principles of testing machine, types, applications

Types of testing machines , universal testing machine, hardness testing machine, impacts testing machine, all theses types are in detail and also about their functions

1. Name Ahmad nawaz Roll no 2k23-P&G-01 Subject Mechanics of material Topic Principles of testing machine Department Petroleum & Gas engineering NFC IET MULTAN Submitted to: Eng Hussain gardezi

2. Principles of Testing machine Introduction What are testing machine? A testing machine is a device used to determine the mechanical properties of materials, such as strength, elasticity, hardness, toughness, and durability. These machines play a critical role in engineering, manufacturing, construction, and quality assurance by ensuring that materials and components meet required standards and specifications. Uses of testing machines : 1. Check material strength – To find out how strong a material is (like steel, rubber, or plastic). 2. Test product quality – To make sure products meet required standards. 3. Measure hardness – To see how hard or soft a material is. 4. Check flexibility – To test how much a material can bend without breaking. 5. Test durability – To find out how long a material or product can last. 6. Safety testing – To make sure products like helmets or car parts are safe to use. 7. Compare materials – To choose the best material for a specific job. 8. Support research – Used in labs for developing new and better materials

3. Types of testing machine Here are the main types of testing machines used in material testing, each designed for a specific kind of force: Universal Testing Machine (UTM)
Hardness Testing Machine
Impact Testing Machine
Torsion Testing Machine The Universal Testing Machine (UTM) is used for testing materials under tension, compression, and bending. The Hardness Testing Machine checks a material’s resistance to indentation using methods like Brinell and Rockwell. The Impact Testing Machine measures a material’s toughness under sudden force, using tests like Charpy and Izod . The Torsion Testing Machine applies twisting force to determine a material’s torsional strength.

4. Universal testing machine Introduction to Universal Testing Machine (UTM) A Universal Testing Machine (UTM) is a mechanical testing device used to perform various tests on materials, such as tensile, compression, bending, and shear tests. It is called “universal” because it can test a wide range of materials and perform multiple types of tests using the same equipment Main Parts of UTM: Load Frame: The main structure that holds everything. Crosshead: Moves up and down to apply the load. Load Cell: Measures the applied force. Grips/Fixtures: Hold the test specimen Control Panel/Computer: Used to operate the machine and record data.

5. Step-by-Step Working Principle of UTM: Step 1: Preparation Select the test type (e.g., tensile, compression, bending).
Choose the right grips/fixtures based on the material and test.
Prepare the test specimen as per required standards (size and shape). Step 2: Mounting the Specimen The test specimen is placed between the machine’s grips (for tensile tests) or on the support fixtures (for bending/compression).
The grips are tightened to hold the specimen securely. Step 3: Zero the Machine The machine is calibrated and set to zero to ensure accurate readings for force and extension. Step 4: Apply Load The machine starts applying force through the crosshead (upward or downward movement).
The load is applied gradually and steadily at a set speed (strain rate).

6. Step 5: Measure Force and Deformation As the force is applied:
The load cell measures the amount of force applied.
The extensometer (or internal sensors) measures how much the material stretches or compresses. Step 6: Record Data The system records real-time data like:
Force vs. displacement
Stress vs. strain
This data is shown in the form of graphs or tables on a computer or display screen. Step 7: Material Failure The machine continues applying load until the material breaks, bends, or deforms permanently (depending on the test).
The peak values (like maximum load, breaking point, yield point) are noted.

7. Step 8: Test Ends & Analysis Once the test is complete:
The machine stops automatically.
The specimen is removed. The recorded data is used to analyze material properties such as: Tensile strength
Compressive strength
Elongation
Modulus of elasticity

8. Advantages & Disadvantages of UTM Advantages Versatile: Can perform many different tests.
Accurate: Gives precise and reliable measurements.
Computer-Controlled: Modern UTMs are automated and user-friendly.
Data Recording: Easy to collect, save, and analyze test results.
Durable: Designed for long-term, heavy-duty use. Disadvantages Expensive: High initial cost for the machine and software.
Requires Training: Needs skilled operators for accurate testing.
Large Size: Takes up space in labs or workshops.
Limited by Fixtures: Requires different fixtures for different tests or materials.

9. Applications of UTM Tensile Testing: Checking how much a material can be stretched before breaking. Compression Testing: Testing how much a material can be compressed or crushed. Bending/Flexural Testing: Measuring the bending strength of materials like wood or plastic. Shear Testing: Determining how a material reacts to shear forces. Material Quality Control: Ensuring materials meet the required strength and standards. Educational Labs: Used in colleges and universities for student training. Research & Development: To develop and compare new materials.

10. Hardness testing machine What is hardness testing machine? A hardness testing machine is a device used to measure how resistant a material is to being scratched, dented, or deformed. It works by pressing a hard object (called an indenter) into the surface of the material and then measuring how deep or wide the mark is. This helps determine how strong or durable the material is. Types of Tests 1. Brinell – Uses a big steel ball and checks the dent size. 2. Rockwell – Measures how deep the tip goes in. 3. Vickers – Uses a diamond shape tip, good for very small or thin things. 4. Mohs – Scratches the material to see how easy it is to scratch.

11. Brinell test Step 1: Prepare the Material
Clean and smooth the surface of the material (metal, etc.) to be tested. Step 2: Choose the Indenter
Use a steel or tungsten carbide ball (usually 10 mm in diameter). Step 3: Apply the Load
Press the ball into the material using a heavy load (usually 500 to 3000 kg).
The load is applied for 10 to 15 seconds. Step 4: Remove the Load
Take off the load and remove the ball.
A round dent (indentation) will be left on the material. Step 5: Measure the Indentation
Use a microscope to measure the diameter of the dent in millimeters. Step 6: Calculate Hardness After making the dent and measuring its diameter, we calculate the hardness using a formula. The Brinell Hardness Number (BHN) tells us how hard the material is.

12. Rockwell test Step 1: Prepare the Material
Clean and smooth the surface of the material to be tested. Step 2: Choose the Indenter
Use either:
A steel ball for softer materials, or A diamond cone (called a brale ) for harder materials. Step 3: Apply Minor Load
First, apply a small load (usually 10 kg) to set the indenter into the surface.This helps remove any surface irregularities. Step 4: Apply Major Load
Next, apply a bigger load (like 60, 100, or 150 kg) on top of the minor load.This creates a deeper dent in the material. Step 5: Remove the Major Load
After a few seconds, remove the major load but keep the minor load applied. Step 6: Measure Depth of Indentation
The machine automatically measures how deep the indenter went into the material.This depth is used to give a Rockwell Hardness Number (HR).

13. Rockwell test machine Hardness test machine

14. Applications Brinell test 1. Used for Soft Metals Checks hardness of metals like aluminum, copper, and cast iron. 2. Used in Factories Helps make sure parts are strong enough before selling or using them. 3. Helps Choose the Right Material Engineers use it to pick the best metal for machines or tools. 4. Checks Heat Treatment Results Used to see if heating the metal made it harder or softer. 5. Tests Big Metal Parts Good for testing large or rough items like pipes or engine blocks. Rockwell test 1.Used for All Types of Metals Can test soft and hard metals like steel, aluminum, brass, and more. 2. Used in Factories for Fast Testing Gives quick results, so it’s great for checking parts during production. 3. Testing Small Parts Good for checking hardness of small items like screws, bolts, and tools. 4. Quality Control Helps make sure the materials used in machines or cars are strong and reliable. 5. Used in Laboratories Common in labs to test and compare different metals easily.

15. Advantages & Disadvantages of brinell & rock well test Brinell test Advantages 1. Easy to Use The test is simple and doesn’t need complex steps. 2. Good for Soft Metals Works well on soft and rough-surfaced materials like cast iron or aluminum. 3. Large Indentation is Easy to Measure The dent made is big and easy to see and measure. Rockwell test Advantages: 1. Very Quick Test Gives results in seconds. 2. Easy to Use No need for microscopes or special measurements. 3. Automatic Reading The machine shows the hardness number directly .

16. Impact testing machine What is Impact testing machine? An impact testing machine is a device used to measure the toughness or impact strength of a material — that is, how much energy a material can absorb during a sudden impact before it fractures. This helps determine how a material behaves under quick loading conditions, such as during collisions or crashes. Common Types of Impact Testing Machines: 1. Charpy Impact Testing Machine Uses a notched specimen.
The specimen is placed horizontally.
A pendulum swings and hits the center of the specimen.
Measures the energy absorbed to break the material.

17. 2. Izod Impact Testing Machine Uses a notched specimen.
The specimen is placed vertically.
The pendulum strikes the upper tip of the specimen.
Also measures energy absorbed in breaking. Main Components: 1. Pendulum: Swings and hits the specimen.
2. Anvil: Holds the specimen in place.
3. Scale/Display: Shows the energy absorbed.
4. Specimen Holder: Ensures correct positioning of the sample.
5. Release Mechanism: Triggers the pendulum swing.

18. Working principle 1. The pendulum is raised to a set height (potential energy).
2. The specimen is clamped in place.
3. The pendulum is released and strikes the specimen.
4. The specimen breaks, and the machine measures how much energy was absorbed during the break. Applications: Material selection for products under impact stress.
Quality control in manufacturing.
Research and development in material science.

19. Advantages and disadvantages of impact testing machine Advantages 1. Simple and Quick Testing:
Provides fast results, making it efficient for quality control.
2. Low Cost per Test:
Once the machine is set up, individual tests are inexpensive.
3. Detects Brittleness:
Easily identifies brittle materials that are prone to sudden failure. Disadvantages 1. Destructive Testing:
The specimen is destroyed in the process and cannot be reused.
2. Not Suitable for All Materials:
Thin, soft, or very ductile materials may not give accurate results.
3. Limited to Certain Shapes/Sizes:
Standard specimens are required; irregular shapes may not be testable.

20. Torsion testing Machine What is torsion testing machine? A torsion testing machine is a device used to test the torsional (twisting) strength and behavior of materials or components. It measures how a material reacts when a torque (twisting force) is applied. This test is important for components like shafts, rods, and wires which often undergo twisting in real-world applications. Main Components: 1. Specimen holder (grips or chucks): Holds the test sample securely at both ends.
2. Drive unit: Applies the twisting force (torque) to one end of the specimen.
3. Torque measuring device: Measures the torque being applied.
4. Angular displacement indicator: Measures how much the specimen has twisted (in degrees or radians).
5. Dial gauge or digital display: Shows the torque and angle of twist during the test.

21. Working Principle: One end of the specimen is fixed.
The other end is rotated to apply torque.
As torque increases, the specimen twists.
The machine records the torque and the angle of twist.
The test continues until the material yields (deforms permanently) or fractures. Purpose of Torsion Test: To determine modulus of rigidity (shear modulus).
To find torsional strength and angle of twist.
To study the ductility and brittleness of materials.

22. Applications: 1. Cars and Bikes: Used to test parts like axles, shafts, and steering rods to make sure they don’t break when they twist while driving. 2. Airplanes: Helps check if aircraft parts can handle twisting forces during flying and turning. 3. Buildings and Bridges: Tests steel rods and construction materials to see if they can handle twisting during earthquakes or strong winds. 4. New Materials: Scientists use it to check how strong and flexible new materials are when twisted.

23. Advantages and disadvantages of torsion testing Advantages Accurate data on material’s twisting strength.
2. Helps test materials under twisting (torsional) stress, like shafts and rods.
3. Provides useful information for designing parts in automotive and aerospace industries.
4. Measures shear strength and torsional rigidity. Disadvantages Limited to testing materials with a circular cross-section (e.g., rods, wires).
2. Expensive and requires specialized equipment.
3. Not as widely available as other machines like Universal Testing Machines (UTM).

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