SIDDHARTH KRISHNA J

EXPERIMENT 4 203224023
Group 4
TENSION TEST ON HYSD BARS

07.10.2024

AIM:

• To determine the tensile strength, elastic and inelastic properties of Ductile Steel and to
study its behaviour.
• The specific properties to be determined are
o Modulus of Elasticity
o Ultimate Tensile Stress
o Nominal and Actual Breaking Stress
o Percentage Elongation
o Percentage Reduction in Area
o Proof Stress

MATERIALS AND EQUIPMENT:

• Universal Testing Machine

• Extensometer
• Vernier calliper
• Meter Scale
• Chalk for marking gauge length

THEORY:

The tension test is one of the most fundamental tests used to determine the mechanical
properties of materials such as mild steel, high yield strength deformed (HYSD) bars, and other
structural materials. It provides essential data on how a material behaves under axial tensile stress
and gives insight into various properties like strength, elasticity, and ductility.

The primary purpose of a tension test is to understand how materials respond when subjected
to tensile forces. By applying a gradually increasing axial force until the material fractures, the test
helps identify the material's mechanical characteristics, including:
 • Elastic Behavior: The region where the material deforms but returns to its original shape
after the load is removed.
• Plastic Behavior: The region where permanent deformation occurs, and the material does
not return to its original shape after the removal of load.
• Ultimate Strength: The maximum stress the material can withstand before failure.
• Fracture Point: The point at which the material fails completely.

Stress-Strain Curve:

A tension test typically results in a stress-strain curve, which provides a visual representation
of the material’s behavior during loading:

• Elastic Region: The initial linear portion of the curve where stress is proportional to strain
(Hooke’s Law). The slope of this region gives the modulus of elasticity.
• Yield Point: The point where the material begins to deform plastically.
• Plastic Region: After the yield point, the curve flattens, and the material experiences
permanent deformation.
• Ultimate Strength: The peak of the curve where the material reaches its maximum load-
carrying capacity.
• Fracture Point: After reaching the ultimate strength, the material eventually breaks at the
fracture point.

The stress-strain graphs for mild steel and HYSD bars differ due to their distinct material
properties and mechanical behavior under tensile loading. The key differences between these two
types of materials:

Property Mild Steel HYSD bars

No distinct yield point (0.2% proof
Yield point Clearly defined yield point
stress)
Gradual transition with no yield
Elastic to Plastic transition Sharp transition with yield plateau
plateau

Ultimate tensile strength (UTS) Lower UTS Higher UTS

Ductility Higher ductility, larger elongation Lower ductility, limited elongation

Strain Hardening Pronounced strain hardening Limited strain hardening

Fracture behaviour Significant necking before failure Less necking before failure
PROCEDURE:

1. Measurement of Initial Dimensions:

• The given steel rod was first weighed, and its length was measured.
• The average diameter “d” of the rod was determined using the density of the specimen.

2. Marking the Gauge Length:

• The center point of the rod was marked using chalk.

• Marks were then made on either side of the center mark at a distance of 5 times the bar
diameter, which is the gauge length for the test.

3. Mounting the Rod in the Universal Testing Machine (UTM):

• The rod was securely fixed in the tension grips of the Universal Testing Machine (UTM).
• An extensometer was then firmly attached to the rod, ensuring that its axis coincided with
the axis of the specimen. Any zero error in the extensometer and the UTM was eliminated.

4. Recording Extensometer Readings:

• The load was applied incrementally within the elastic limit of the material.
• At each load increment, extensometer readings were taken for both the left and right sides
to measure the elongation of the rod accurately.

5. Loading Beyond Yield Point:

• The load was applied continuously until the yield point of the rod was reached. At this
point, the extensometer was removed.
• The load was then increased further to determine the ultimate load and the breaking load
of the rod.

6. Measuring Final Dimensions:

• After the rod fractured, the final diameter (d') was measured at the necked section of the
rod.
• The broken parts were carefully placed together, and the final length (l') between the
previously marked chalk marks was measured to calculate the elongation of the bar.

7. Calculations:

• The necessary calculations were performed to determine key properties of the material.
FORMULAE USED: Where:

E = Young's Modulus
∆σ
1. Young’s Modulus (E): E=
∆ε σ = Direct Stress
π
2. Area of the Rod (A): A = d2 ε = Strain
4
Ultimate load
3. Ultimate Stress (N/mm2) = d = Diameter of the rod (mm)
Area of Cross−section
Breaking Load l – Initial length
4. Normal breaking Stress (N/mm2) =
Area of Cross−section
Breaking Load l’– Final length
5. Normal breaking Stress (N/mm2) =
Final Area of Cross−section
d1 – Initial diameter of the rod
l′ −l
6. Percentage Elongation = x 100
l d2 – Final diameter of the rod
2 2
πd1 −πd2
7. Percentage Reduction in Area = 2
πd1

OBSERVATIONS:

1. Weight of the rod (W) = 0.835 Kg

2. Length of the rod (L) = 1000 mm

3. Density of the rod (p) = 7850 Kg/m3

4. Area of cross section of the rod (A) = 106.3584 mm2

5. Diameter of the rod (d) = 11.637 mm ≈ 12 mm

6. Gauge Length = 60 mm

7. Final gauge Length = 70.41 mm

8. Final Diameter (d') = Avg (9.11mm,9.59mm) = 9.35 mm

9. Yield Load – 7600 kg

10. Breaking Load – 7200 kg

11. Ultimate Load – 8900 kg

12. Least count of Extensometer – 0.01 mm

13. Grade of Steel = Fe500

 UTM applying Tension on Recording Extensometer HYSD bar after failure
HYSD bar readings

CALCULATION TABLE:

Average
Extensometer reading extension Youngs
Load Load Stress Strain
S.No. x L.C. Modulus
(Tons) (N) (N/mm2) (x 10-4)
(x 105)
Left Right Average (mm)

1 0 0 0 0 0 0 0 0 -

2 0.5 4905 0.5 0.5 0.5 0.005 46.118 0.5 9.2235277

3 1 9810 3 2.5 2.75 0.028 92.235 2.8 3.3540101

4 1.5 14715 5 4 4.5 0.045 138.353 4.5 3.0745092

5 2 19620 8 7.5 7.75 0.078 184.471 7.8 2.3802652

6 2.5 24525 10 9 9.5 0.095 230.588 9.5 2.4272441

7 3 29430 13 11 12 0.12 276.706 12 2.3058819

8 3.5 34335 15 14 14.5 0.145 322.823 14.5 2.2263688

9 4 39240 18 17.5 17.75 0.178 368.941 17.8 2.0785415

10 4.5 44145 20 19 19.5 0.195 415.059 19.5 2.1285064

11 5 49050 22 22 22 0.22 461.176 22 2.0962563

12 5.5 53955 25 24 24.5 0.245 507.294 24.5 2.0705879

13 6 58860 28 26.5 27.25 0.273 553.412 27.3 2.0308685

GRAPH:

1.Load vs Elongation

Load vs Elongation for HYSD bar

7

5
Load (Tons)

0
0 0.05 0.1 0.15 0.2 0.25 0.3
Elongation (mm)

2. Stress vs Strain

Stess v/s Strain for HYSD bar

600

553.412

500 507.294

461.176

415.059
400
368.941
STRESS (MPa)

322.823
300
276.706

230.588
200
184.471

138.353
100 92.235

46.118
0 0
0 0.0005 0.001 0.0015 0.002 0.0025 0.003
STRAIN
CALCULATIONS:

π
• Area of the specimen, A = x 11.6372 = 106.358mm2
4

W 835
• Diameter of the specimen, d = √π = √π = 11.637 mm
p (7.85)
4 4

l′ −l 70.41−60
• Percentage elongation = ( ) x 100 = ( ) x 100 = 17.35%
l 60

𝜋𝑑12 −𝜋𝑑22 𝜋∗11.6372 −𝜋∗9.352

• Percentage Reduction in Area = = x100 = 35.44%
𝜋𝑑12 𝜋∗11.6372
𝑈𝑙𝑡𝑖𝑚𝑎𝑡𝑒 𝑙𝑜𝑎𝑑 8900∗9.81
• Ultimate Stress (N/mm2) = =𝜋 = 820.894 N/mm2
𝐴 ∗11.6372
4

𝑌𝑖𝑒𝑙𝑑 𝑙𝑜𝑎𝑑 7600∗9.81

• Yield Stress (N/mm2) = = 𝜋 = 700.988 N/mm2
𝐴 ∗11.6372
4

𝐵𝑟𝑒𝑎𝑘𝑖𝑛𝑔 𝑙𝑜𝑎𝑑 7200∗9.81

• Nominal Breaking Stress (N/mm2) = =𝜋 = 664.09 N/mm2
𝐴 ∗11.6372
4

𝐵𝑟𝑒𝑎𝑘𝑖𝑛𝑔 𝑙𝑜𝑎𝑑 7200∗9.81

• Actual Breaking Stress (N/mm2) = = 𝜋 = 1028.7 N/mm2
𝐴′𝑒 ∗9.352
4

4905
• Stress @ 0.5Tons, σ = 106.358 = 46.118 N/mm2
1×0.05
• Strain @ 0.5Tons, ε = = 0.5x10-4
100

• Young's Modulus, Slope of Stress Vs Strain Graph E= ∆σ/∆ε = 193917.47 N/mm2

Young's Modulus, calculated from the slope of

the best-fit line for the Stress vs Strain
RESULTS:

• Young’s modulus (E) = 1.939 x 105 MPa

• Ultimate tensile stress (N/mm2) = 820.894 MPa
• Yield Stress (N/mm2) = 700.988 MPa
• Nominal breaking stress = 664.09 MPa
• Percentage of elongation = 17.35%
• Percentage of reduction of area = 35.44%
PRECAUTIONS:

• The gauge length should be clearly marked and indicated along its entire circumference.
• The clamps of the Universal Testing Machine (UTM) should be securely fastened.
• Caution must be exercised as the specimen approaches its breaking load.

CONCLUSION:

• The tensile test showed a yield strength of 700.988 MPa, which is very high compared to
nominal yield strength of Fe 500 (500 MPa).
• The actual yield strength of Fe500 steel is often higher than 500 MPa because the
characteristic yield strength is the minimum value below which only 5% of the material is
expected to fail. Manufacturers ensure higher quality to meet safety standards, resulting
in yield strengths that typically exceed 500 MPa.
• But the tremendous difference in strength could be due to the following reasons.
o Material property: The material could be of superior quality.
o Heat treatment: Heat treatment can enhance its strength beyond the standard
specifications.
o Defects in testing: There might be slippage during testing which can cause errors in
reading.
o Error in readings
o Strain hardening

INFERENCE
The experiment successfully determined the mechanical properties of the HYSD 500 bar,
including its Young’s Modulus, which was found to be 193.9 GPa. While the results align with
expected mechanical behavior, minor deviations could stem from material inconsistencies or
testing conditions.

REFERENCE:

• IS 1608 (2005): Mechanical testing of metals – Tensile Testing