1.

0 ABSTRACT

A torsion test was conducted by Group 1-6 in order to examine the relationship between the torque and
angle of twist of the materials being tested. The main objective was to determine parameters such as the
maximum shearing stress, shear stress at the proportional limit, shear modulus, and rigidity modulus. The
test focused on a brass rod as the subject of an investigation to analyze its characteristics.

Before initiating the test, the torsion testing equipment underwent calibration. Subsequently, the specimen
was securely attached to the testing apparatus. The applied torque and twist angle were carefully recorded
for each unit of strain. The model was subjected to increasing levels of torque until it eventually fractured.
The resulting data will be used to generate a stress-strain graph and a graph showing the relationship
between the angle of twist (in radians) and the applied torque. These graphs will be included in the lab
report.

2.0 TITLE

Torsion Test

3.0 INTRODUCTION

When moments or torques are applied to a straight bar, it has the tendency to undergo twisting around its
longitudinal plane. For instance, when using a screwdriver, applying a torque T to the handle causes the
shank of the screwdriver to twist. Torsion bars are also commonly found in various applications such as
drill bits, axles, propeller shafts, steering rods, and drive shafts in vehicles.

Ideally, in a perfect scenario, one end of a straight bar would be fixed and supported, while the other end
would be subjected to equal and opposite forces. This is the most effective way to apply torsional loading
to a straight bar. The bar experiences twisting around its longitudinal axis due to movement in one
direction at one end and stability or movement in the opposite direction at the other end. In the field of
statics, the moment of a couple is calculated by dividing the magnitude of one force by the angle at which
the lines of action intersect.

Considering torsion is crucial in engineering, as it has a significant impact on various engineering

applications and components. Turbines serve as a notable example of torsion utilization. Imagine a setup
where a gearbox shaft connects an electric generator and a steam turbine. The blades of the turbine are
propelled by the power of steam generated in the combustion chamber, causing them to rotate. This
rotational motion generates kinetic energy, which, in turn, induces the rotation of the gearbox shaft. The
shaft experiences an equal and opposite torque applied by the generator, resulting in the shaft spinning
inside the generator and releasing energy.
 Figure 1: Torsion testing machine

4.0 OBJECTIVES

From the relationships between torque and angle of twist of the tested materials we carry out the torsion
test to determine :

a) The shear modulus or modulus of rigidity,

b) The maximum shearing stress,
c) The shear stress at the proportional limit

5.0 EQUIPMENT/APPARATUS

1.TecQuipment Torsion Testing Machine

2. Torque meter
3. Torsion test brass specimen
4. Digital vernier calliper
5. Permanent marker pen

6.0 LITERATURE REVIEW

In a twisted cylindrical bar, the angle of the twist depends on its length and the applied torque. Shear stress
within the bar resists the twisting force, with zero shear stress at the center and increasing towards the outer
surface. The bar's radius linearly increases until reaching its maximum size, resulting in the highest shear stress
at the outer surface.
7.0 PROCEDURES

1. The apparatus was set up as in the figure above.

2. The specimen's initial diameter, length, and gauge length were measured and noted.

3. A line was drawn using a permanent marker down the length of the test specimen to observe the degree
of rotation during the application of the twisting moment.

4. The testing apparatus was calibrated.

5. The test specimen was fitted with input and torque shafts at both ends, and hexagonal sockets
were used to secure it to the torsion testing equipment. The torque meter's reading was set to
zero.

6. The specimen was bent until failure occurred at strain increments of 0.5. For the purpose of building
a relationship between torque (T) and angle of twist (t), the rotational data was entered into a table.

7. The specimen's final diameter, total length, and gauge length were all measured and noted.

8. Torque and angle of twist were used to create the relationship between shear stress and shear strain.
The maximum shear stress, shear stress at the proportional limit, and rigidity modulus were calculated.

9. The natures of the fracture surfaces of failed specimens were sketched.

10. Whenever it was practicable, the measured data, findings, graphs, and comparisons with theoretical
predictions were discussed. Possible causes of errors or deviations were discussed.

11. Recommendations for improvement of the experiment were proposed.

8.0 DISCUSSION

As long as the applied torque does not exceed the proportionality limit, the theory states that the torque is
inversely proportional to the angle of the twist. At this point, the specimen can still return to its original
shape and size after the applied force is removed. However, beyond the yield point, the specimen
undergoes plastic deformation and is unable to fully recover its original dimensions. If the applied force
continues to increase, the specimen will eventually reach the fracture point, fail, and break. In this
experiment, it was discovered that the shear stress within the proportional limit is 60.03 MPa.

The experiment resulted in a shear modulus of 15.813 GPa. According to Hooke's Law, the shear
modulus is the ratio of shear stress to shear strain. Graphs 1 and 2, which depict torque versus angle of
twist, have a similar shape to the stress-strain graph. Although the curves may appear similar, they are not
identical. The similarity in shape indicates that the torque angle of the twist graph and the stress-strain
graph share certain properties that can be derived from the graph. If a shear stress-shear strain curve
(Graph 2) is derived from the torque angle of the twist curve, the property within the proportional limit is
known as the modulus of rigidity (or shear modulus), similar to the determination of the modulus of
elasticity within the elastic region of the stress-strain curve.

The fracture surface of the specimen exhibits a relatively flat profile. This smooth fracture surface
indicates that the brass specimen, being a ductile material that is weak against shearing stress, collapsed
under the maximum shearing stress. Furthermore, the fracture occurred at the fillet on the right side of the
shaft, which acted as a stress concentrator. While the right socket provided support, the shaft could rotate
from the left end. Consequently, shear stress increased at the small diameter of the shaft, near the stress
concentration point, ultimately leading to the shaft's failure. The shear stress-shear strain graph shows no
necking zone, as torsion failure is often caused by local buckling. The inner material will maintain the
shape of the outer fibers or remain flat since the specimen was not loaded to failure.

According to the stress-strain graph, there should be a peak between the proportional limit and the
breaking point. This peak represents the highest torque applied before necking occurs. However, the
experiment encountered some issues. The torsion testing apparatus was highly sensitive, and even slight
movements could affect the torque, resulting in inconsistent and inaccurate results. The screw tightener
could break, leading to inconsistent values. The rapid application of torque also caused the specimen to
fail more quickly due to the varying rate. To achieve a smooth graph and accurate results, it is crucial to
apply torque continuously at a consistent rate.

Several precautions have been implemented to enhance the accuracy of this experiment:

● Prior to commencing the experiment, ensure that both the torque meter and revolution counter are
set to zero.
● Secure the specimen firmly in place.
● If necessary, calibrate the machine before conducting the experiment.
 ● The torsion testing apparatus is highly sensitive, even to slight movements. Therefore, torque
measurements should be taken once oscillations cease or, if fluctuations are minimal, the average
value can be used.
● Begin with a small twist angle and gradually increase the applied torque to obtain sufficient data
points for mapping the elastic zone.

While tension and torsion tests differ in the manner in which forces are applied to the material, both
methods are employed to determine mechanical properties. Tension testing involves subjecting the
material to a uniaxial load along its axis, aiming to assess its resistance to deformation or failure under
tensile stress. This test is commonly utilized to determine the ultimate tensile strength, yield strength, and
elongation of a material. On the other hand, torsion testing involves twisting the test object around its axis
to evaluate its resistance to deformation or failure under torsional stress. Torsional testing is frequently
used to determine the shear modulus, shear yield strength, and other relevant properties. In essence,
tension tests measure a material's response to stress or stretching, while torsion tests assess its behavior
under twisting or shearing.

The torsion test is crucial in various engineering applications. Three notable examples include:

● Turbines: Turbines employed in electricity generation experience torsional loads due to the
rotational forces generated by the rotor. Torsion testing is essential for assessing the torsional
strength and stiffness of turbine shafts, which play a critical role in transmitting power from the
turbine to electrical generators.

● Generators: Electrical generators are also susceptible to torsional loads caused by rotor rotation.
Torsion testing is necessary to evaluate the torsional strength and fatigue characteristics of rotor
shafts and coupling components, which are crucial for transmitting power from the turbine to the
electrical grid.

● Industrial Machinery: Machinery components such as gears, drive shafts, and couplings in
various industries like manufacturing, mining, and oil & gas are subjected to torsional loads
during operation. Torsion testing is vital in determining the torsional strength and fatigue
properties of these components, ensuring their ability to withstand the loads and maintain
consistent performance throughout their service life.

9.0 CONCLUSION

The specimen (a brass rod) had a shear modulus from the experiment of 15.813 GPa with a
percentage error of 60.47 %. At the proportional limit, the shear stress is 60.03 MPa. According to
the experiment's graphs, applied torque is exactly proportional to the twist angle, and shear stress is
directly proportional to shear strain up to the yield point, which is 60.03 MPa at 0.209 radians of
shear strain. The specimen remains elastic in this area, and Hooke's law is followed. Beyond this limit,
plastic deformation occurs, the shear stress and strain are no longer proportionate, and the applied torque
and twist angle are no longer proportional. The specimen will ultimately get close to its fracture point, or
the point at which it can withstand the most shear stress, and fail and shatter if the applied torque is
kept constant. 200 MPa is the maximum shear stress. All of the experiment's goals have been
achieved.

10.0 REFERENCES

1. Lab Sheet

2. Lab demonstration videos

3. Mechanics of Materials textbook

Beer, F. P., Johnston, E. R., DeWolf, J. T., & Mazurek, D. F. (2012). Mechanics of
Materials (6 ed.). New York: McGraw-Hil.

Farrukh, H., & Arif, M. (2017). Engineering Practical Book Vol-II: Basic Mechanics
and Science of Materials. New Delhi: Educreation Publishing.

Gere, J. M. (2004). Mechanics of Materials (6 ed.). Belmont: Thomson Learning Inc

11.0 APPENDIX