ISE 4500

Material Testing of
Solids
Thursday 2:20pm Group D1

Gregory Massey, Nicholas Leight, Roxanne

Manger, Indushekhar Kumar, Brian Luriab

Introduction
In this lab a manufacturing process was analyzed to determine the precision and accuracy of
machining that was taking place, several different features were measured using dial calipers to
attempt to understand what trends were occurring during manufacturing. The experience gained
will help reduce wasted cost, material and labor by helping to predict when a machine tool is
worn or damaged in such a way that it will no longer produce parts within tolerance. This
prediction will allow operators to take preventive action and replace or repair the tools before
any scrap parts are produced.
During the lab a tensile test was also performed on an aluminum sample. The test was
performed to improve the understanding of how materials act under extreme load. Using the
data collected during the test, the material properties of the sample were determined as well as
the true stress true strain relationship. This information is a critical aspect of mechanical design
as without a sufficient knowledge of the material properties that you are building something
from, you are doomed to produce a part that is either to heavy or dangerously weak.

Part 1
1)
Part #
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20

D1
0.764
0.764
0.765
0.764
0.764

D2
0.628
0.623
0.625
0.630
0.627

D3
0.501
0.506
0.535
0.530
0.508

L3
0.629
0.646
0.644
0.651
0.664

L4
1.806
1.781
1.784
1.774
1.805

0.746
0.766
0.746

0.626
0.626
0.624

0.493
0.501
0.502

0.639
0.626
0.641

1.789
1.789
1.784

0.746
0.764

0.632
0.627

0.498
0.502

0.651
0.633

1.811
1.788

0.764
0.765
0.764

0.628
0.628
0.628

0.502
0.501
0.532

0.626
0.679
0.716

1.773
1.779
1.803

0.765
0.764
0.764

0.628
0.619
0.627

0.501
0.508
0.503

0.645
0.649
0.659

1.786
1.779
1.781

2)
Upper Control Limit=Mean +3S
Lower Control Limit=Mean3S

Mean=xbar=

xi
n

x
( ixbar )2
n1
Standard Deviation=S=

Sum of
D2
10.026

Mean of
D2
0.626625

Par
t#
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20

(D2-Mean)^2
1.89063E-06
1.31406E-05
2.64062E-06
1.13906E-05
1.40625E-07
3.90625E-07
3.90625E-07
6.89062E-06
2.88906E-05
1.40625E-07
1.89063E-06
1.89063E-06
1.89063E-06
1.89063E-06
5.81406E-05
1.40625E-07

Variance=(S)^2
8.78333E-06

Standard
Deviation
0.002963669

Upper
Control
Limit
0.63551601

Lower
Contro
Limit
0.6177

Control Chart for D2

0.64
0.64
0.63
D2

0.63
Diameter (in)

Mean of D2

0.62

Upper Contol Limit

0.62

Lower Control Limit

0.61
0.61
2
1

4
3

6
5

8 10 12 14 16 18 20
9 11 13 15 17 19

Part Number

Mean= 0.6266, UCL=0.6355, LCL=0.6177

Control Chart for D2 (3S=+-0.005)

0.63
0.63
0.63
0.63
D2

0.63
Diameter (in)

Mean of D2

0.62

Upper Contol Limit

0.62

Lower Control Limit

0.62
0.62
0.62
2
1

4
3

6
5

8 10 12 14 16 18 20
9 11 13 15 17 19

Part Number

3)
Mean= 0.6266, UCL= 0.6316, LCL= 0.6216
This process is not in-control when its control chart uses 3S= +-0.005 because part 11 and 19
are outside the upper and lower control limits. It is also important to note that the process does
not appear to have an overall trend within the testing window we were provided. However, there
are some random peaks and valleys in the data which may indicate that there the machines in the
process could have been experiencing some random vibrations in the tools.

Part 2
1) Initial length=2
Force
(lbf)

Elongation
(in)

1000

0.0007

2000

0.0016

3000

0.0025

4000

0.0033

5000

0.0044

5500

0.0049

6000

0.0053

6500

0.0059

7000

0.0064

7500

0.007

8200

0.0075

8300

0.01

8400

0.0125

8450

0.015

8800

0.017

9000

0.0625

10000

0.09

7800

0.31

Engineering
Stress (psi)
4972.89265
9
9945.78531
7
14918.6779
8
19891.5706
3
24864.4632
9
27350.9096
2
29837.3559
5
32323.8022
8
34810.2486
1
37296.6949
4

Engineering Strain

True Stress

Actual Area

0.00035

4974.633171

0.201019847

0.0008

9953.741945

0.200929461

0.00125

14937.32632

0.200839155

0.00165

19924.39173

0.200758952

0.0022

24919.16511

0.200648777

0.00245

27417.91935

0.200598737

0.00265

29916.42494

0.200558724

0.00295

32419.1575

0.200498733

0.0032

34921.64141

0.200448768

0.0035

37427.23337

0.200388843

40777.7198
41275.0090
7
41772.2983
3
42020.9429
7

0.00375

40930.63625

0.200338933

0.005

41481.38411

0.200089755

0.00625

42033.3752

0.199841197

0.0075

42336.10004

0.199593255

43761.4554
44756.0339
3
49728.9265
9
38788.5627
4

0.0085

44133.42777

0.199395344

0.03125

46154.65999

0.194996562

0.045

51966.72828

0.192430817

0.155

44800.78996

0.174104073

True Strain
0.0003499
4
0.0007996
8
0.0012492
2
0.0016486
4
0.0021975
8
0.002447
0.0026464
9
0.0029456
6
0.0031948
9
0.0034938
9
0.0037429
9
0.0049875
4
0.0062305
5
0.0074720
1
0.0084640
8
0.0307716
6
0.0440168
9
0.1441003
4

.506 /2 right )} ^ {2} =.20109 i {n} ^ {2}

2
Initial Area=(intial radius ) =
Engineering Stress=

Force
Initial Area

Engineering Strain=

Elongation
Initial Gauge Length

True Stress=

Force
Instantaneous Area

True Strain=ln

length
( Instantaneous
)
Initial length

Instantaneous Area=

Initial AreaInitial Gage Length

Instantaneous Length

Instantaneous Length=Initial gauge length+elongation

Stress vs Strain
60000

Engineering Stress vs Strain

50000
40000

Stress (psi)

Moving average (Engineering Stress vs Strain)

30000
20000 True Stress vs Strain
10000
0 Moving average (True Stress vs Strain)
0
0.02 0.04 0.06 0.08 0.1 0.12 0.14 0.16 0.18
Strain

2)

Ultimate Tensile Strength=

Ductility %EL=

Fmax
10000
=
=49728.93 psi
Initial Area 0.20109

Elongation at break
100 =0.31 } over {2100 =15.5
Initial gauge length

.20109 } * 100%=35.3 %
Initial areafinal area
.20109 - .1301
Ductility %AR=
100 =

Initial area

Stress vs. Strain Elastic Region

40000
f(x) = 11075382.41x
R = 1

35000
30000
25000

Stress(psi)

20000
15000
10000
5000
0
0

Strain

3)

Elastic Modulus=11,100 ksi

Stress vs Strain (0.2% Yield Offset)

45000
40000
Engineering Stress vs Strain

Moving average (Engineering Stress vs Strain)

35000
30000
25000
True Stress vs Strain
Stress (psi)
20000

Moving average (True Stress vs Strain)

15000
10000
5000
0
0

0.01

0.01

0.01

0.01

0.01

Strain

4)

The slope of the yield offset line is equal to the elastic modulus (11,100,000 psi). A new line with
this slope was created from 2 points, one at (.002, 0) and one at (.002+.01, .01*11,100,000). The
yield strength was found where this line intersected the stress/strain curve. The yield strength
was found to be about 41,500psi.

0.01

5.)
True Stress
(ksi)
4.97263169
9.949737182
14.93131648
19.9163754
24.9091392
27.40688809
29.90438845
32.40611405
34.90759112
37.41217499
40.91416832
41.4646946
42.01646359
42.31906664
44.11567123
46.13609024
51.94582012
44.78276492

Strain
0.000349939
0.00079968
0.001249219
0.00164864
0.002197584
0.002447004
0.002646495
0.002945657
0.003194891
0.003493889
0.003742986
0.004987542
0.00623055
0.007472015
0.008464078
0.030771659
0.044016885
0.144100344

K
7.057496037
13.61705811
20.03761357
26.40321207
32.60717109
35.70752948
38.82731851
41.8777113
44.9493913
47.98520507
52.31811946
52.35660337
52.53640317
52.49341423
54.42261249
53.77273769
59.59795497
48.76740459

True Stress vs Strain

100

10

log(True Stress (ksi))

1
0

0.01
log(Strain)

0.1

Looking at true stress and strain graph the necking point is approximately the highest point on
the graph, which is the second to last data point. The strain at this value is approximately equal to
the strain hardening exponent, which is 0.044.
=K

Using the equation above the strength coefficient can be found at every data point, then take the
average of these values for the most accurate value.
n
Average K (ksi)

0.044
40.85194203

6.) Measuring a gauge that includes the necked region yields the elongation at break because
when the part starts necking, it starts necking in that one location. So measuring this region will
help to determine how much elongation there was in the necked region before the part failed.
Oppositely measuring a gauge that does not include the neck yields the elongation at the ultimate
load because the ultimate load is located at the peak in the stress strain curve right before
necking occurs. This means the elongation at the ultimate load does not include elongation from
necking and is why a gauge that does not include the neck is measured.