(MDB3023) ENGINEERING MATERIALS

FINAL PROJECT REPORT

Submitted for:

AP Dr Othman Bin Mamat

Date of Submission:

27th July 2016

Prepared by: (GROUP 2)

VEENOSHINI A/P SUPPARMANIAM (19606) - LEADER
UMAR IKHWAN BIN MOHD ROZAIDDIN (19623)
AHMAD YUSUF BIN AMIRUDDIN (19626)
YUKTESVARANATH A/L KATHIRASAN (19639)
NAVIND A/L TAMILSELVAN (19643)

TABLE OF CONTENT
NUM.
1

SUBJECT
PROJECT BACKGROUND
1.1 Sample Description

1.2 Problem Statement

1.3 Objective

1.4 Scope

5 - 10

METHODOLOGY
3.1 Testing Methodology

LITERATURE REVIEW
2.1 Flexural

PAGE
NUMBER

11 12

3.2 Task Division

13

3.3 Gantt Chart

14

RESULTS
4.1 Results Table
4.2 Material Determination

15
16

DISCUSSION

17

CONCLUSION

17

REFERENCES

18

APPENDICES

18 - 22

MINUTES OF MEETINGS

23

PROJECT BACKGROUND

(1.1) Sample Description

1. Physical appearances
Colour cloudy white opaque
Shape rectangular strip
Dimensions 12.5 mm x 126 mm x 3.2 mm (W x L x H)

2. Mechanical characteristics
Hard
Light
Moderately flexible
Smooth surface

3. Optical characteristics
Slightly transparent

4. Material Class
Most probably plastic

(Figure 1.0) Schematic Drawing of the material given. [SCALE 1mm: 1.25mm]

(1.2) Problem Statement

As one of our course requirement, we are assigned to determine the type of material and the
mechanical properties of the sample that was assigned to our group. Based on our observation
and the obvious physical properties, it is most probably a polymer. Nevertheless we need to
prove whether it is polymer or not. Therefore the most suitable in-lab test to perform is the
Flexural test. The two properties we could determine from our lab testing are the Flexural
Strength and the Modulus of Elasticity of our sample. Based on results obtained, the specific
type of polymer could be determined.

(1.3) Objectives

The objectives of this project are summarized in the following points:

1. To determine at least two of the mechanical properties of polymer by conducting
mechanical lab testing using equipment available in the laboratory.
2. To decide the type of material classification for our sample.

(1.4) Scopes
There are only two test that is possible could be carried out for this sample, regarding shape
and availability of testing machine in UTP. That is Hardness test and Flexural test, but due to
some constraints Hardness test could not be conducted.

Flexural Test

We proceeded with three-point-bending test to determine two mechanical properties that are
Flexural Strength and Modulus of Elasticity of the given sample.

LITERATURE REVIEW

(2.1) FLEXURAL

The flexural test measures the force required to bend a beam under three point loading
conditions. The data is often used to select materials for parts that will support loads without
flexing. Flexural modulus is used as an indication of a materials stiffness when flexed. Since
the physical properties of many materials (especially thermoplastics) can vary depending on
ambient temperature, it is sometimes appropriate to test materials at temperatures that simulate
the intended end use environment (Hibbleler, 2005).

Smooth rectangular specimens without notches are generally used for bend testing under threepoint or four-point bend arrangements as shown in figures 1 a) and b) respectively.

(Figure 2.0) Bend testing of a rectangular bar under a) three-point bend and b) four-point
bend arrangements

Figure 2 illustrates three (point bending which is capable of 180 degrees bend angle for welded
materials.

(Figure 3.0) Example of bend testing under a three-point bend arrangement

Considering a three point bend test of an elastic material, when the load P is applied at the
midspan of specimen in an x-y plane, stress distribution across the specimen width as
demonstrated in figure 3 (a) (Dowling, 1999). The stress is essentially zero at the neutral axis
N-N. Stresses in the y axis in the positive direction represent tensile stresses whereas stresses
in the negative direction represent compressive stresses. Within the elastic range, brittle
materials show a linear relationship of load and deflection where yielding occurs on a thin layer
of the specimen surface at the midspan. This in turn leads to crack initiation which finally
proceeds to specimen failure. Ductile materials however provide load-deflection curves which
deviate from a linear relationship before failure takes place as opposed to those of brittle
materials previously mentioned. Dowling (1999) also stated it is also difficult to determine the
beginning of yielding in this case. The stress distribution of a ductile material after yielding is
given in figure 3 (b). Therefore, it can be seen that bend testing is not suitable for ductile
materials due to difficulties in determining the yield point of the materials under bending and
the obtained stress-strain curve in the elastic region may not be linear. The results obtained
might not be validated. As a result, the bend test is therefore more appropriate for testing of
brittle materials whose stress-strain curves show its linear elastic behaviour just before the
materials fail (Dowling, 1999).

(Figure 4.0) Stress distributions in a rectangular bar when a) elastically bended and b) after
yielding

Dowling (1999) and Hibbleler (2005) stated that for brittle materials having a liner stress-strain
relation, the fracture stress (f) can be determined from the fracture stress in bending according
to a linear elastic beam analysis as shown in equation 1

f =

I=

where

3
2 2

2 3
3

.. (1)

..(2)

is the bending moment

is half of the specimen width as shown in figure 1
is the thickness of the specimen as shown in figure 1
is the moment of inertia of the cross-sectional area
7

Under there-point bending in figure 1 a) when the load P is applied at the midspan of a
rectangular bar of a length L between the two rollers, the highest bending moment at the
midspan is

M=

..(3)

We then have

fb =

Where

2 2

2 =

.. (4)

fb is the calculated fracture stress

is the fracture load obtained from the bending test
is the width of the specimen of length = 2c

The determination of the yield strength ( y) is carried out by replacing the load at yielding
Pf in equation 4. The yielding load is determined at the definite yield point or at certain %
offset. Hence, we now have the yield strength in equation 5. It should be noted that the yield
strength obtained from the bend test is not different from the yield strength achieved from the
tensile test. This is because the relationship between the load and the deflection remains
linear at yielding.

o =
The flexural strain

3
2 2

.. (5)

is calculated from equation 6 (v is the deflection of the beam)

f =

6
2

.. (6)

Moreover, from the experimental result, we can also obtain the elastic modulus of the
material according to the linear-elastic analysis. The deflection of the beam (v ) from the
center as illustrated in figure 3 can be expressed in equation 6

v=

..(7)

48

where the elastic modulus ( b ) can be calculated from the slope of the load-deflection
curve ( ) dv dP in the linear region as follows

b =

OR

Where

48

32

b =

( )=

3
4 3

)
3(

.. (8)

..(9)

is the slope of the tangent to the straight-line portion of the load-deflection beam.

Most commonly the specimen lies on a support span and the load is applied to the center by
the loading nose producing three point bending at a specified rate. The parameters for this test
are the support span, the speed of the loading, and the maximum deflection for the test. These
parameters are based on the test specimen thickness and are defined differently by ASTM and
ISO. For ASTM D790, the test is stopped when the specimen reaches 5% deflection or the
specimen breaks before 5%. For ISO 178, the test is stopped when the specimen breaks. If the
specimen does not break, the test is continued as far as possible and the stress at 3.5%
(conventional deflection) is reported (Flexural Properties Testing, n.d.).

(Figure 5.0) Typical Stress-Strain Graph

The specimen is assumed to be a kind of plastic. Based on this assumption and the dimension
of the specimen tensile test according to ASTM standards D790 will be conducted to further
confirm the approximation made earlier. Physical properties of many materials especially
thermoplastics can vary depending on ambient temperature, it is sometimes appropriate to test
materials at temperatures that simulate the intended end use environment (ASTM D790, 2011).
The tensile tests will produce a stress strain diagram than can be used to determine the tensile
modulus (Flexural Properties Testing, n.d.).

10

METHODOLOGY
(3.1) Testing Methodology

Introduction:
These test methods cover the determination of exural properties of unreinforced and
reinforced plastics, including high-modulus composites and electrical insulating materials in
the form of rectangular bars molded directly or cut from sheets, plates, or molded shapes. These
test methods are generally applicable to both rigid and semi rigid materials. However, exural
strength cannot be determined for those materials that do not break or that do not fail in the
outer surface of the test specimen within the 5.0 % strain limit of these test methods. These test
methods utilize a three-point loading system applied to a simply supported beam. The standard
used is ASTM D790.
Procedure A, designed principally for materials that break at comparatively small deections.
Procedure B, designed particularly for those materials that undergo large deections during
testing.
Therefore, since we have a thermoplastic material, the suitable procedure for our test would be
Procedure B.
Equipment:

(Figure 6.0) GOTECH AI-7000-S Servo Control System Universal Testing Machine
11

Procedure:
1. Measure the dimensions of the specimen (length, width and thickness), measured to the
nearest 0.01mm.
2. Find the rate of cross-head motion:
2
=
6

.. (10)

R = rate of crosshead motion, mm /min,

L = support span, mm,

d = depth of beam, mm,

Z = rate of straining of the outer ber, mm/mm/min. Z shall be equal to 0.1.

3. A bar of rectangular cross section rests on two supports and is loaded by means of a
loading nose midway between the supports.
4. A support span-to-thickness ratio of 16:1 shall be used unless there is reason to suspect
that a larger span-to-depth ratio may be required, as may be the case for certain
laminated materials.

(Figure 7.0) Three-Point Loading

5. The specimen is deected until rupture occurs in the outer surface of the test specimen
or until a Maximum Strain of 5.0 % is reached, whichever occurs rst.
6. Procedure B employs a strain rate of 0.10 mm/mm/min.

12

(3.2) Task Division

NUM.

NAME

TASK

Veenoshini

Group Leader
Liaising with Project Supervisor regarding all matters (Report
submission and VIVA Presentation Slot Booking)
Discussion
Conclusion

Yusuf

Secretary
Minutes of Meetings
Project Background
Compilation of Reports and Formatting

Umar

Results
Discussion
Methodology and Procedures

Yuktes

Literature Review
References

Navind

Liaising with Lab Technician to discuss the suitable testing

available
Lab Scheduling
Gantt Chart

(Table 1.0) Task Division Table

13

(3.3) Gantt chart

WEEK

10

11

ACTIVITY
PROJECT PREPARATION
Group Formation
Lab Briefing
Sample Collection
Sample Description
Problem Statement
Literature Review
LAB TESTING
Finding Suitable Testing &
Scheduling
24/6

Sample Lab Testing

Results and Discussion
Conclusion
PROJECT ASSESMENT
Submission
Report

of

Progress

Meeting with Lecturer

Submission of Final Report

27/7

Viva Presentation

27/7

: Key Milestones

14

RESULTS
From the lab testing, the three point bend test provides the data shown in the table in Appendix
1.
(4.1) Results Table
The table below is the summarized results of the experiment conforming to ASTM D790
Procedure B with a test speed of 13.550 mm/min.
Test
No.
1
2

Span
mm
51.000
51.000

Width
mm
12.500
12.500

Max.
Load N
130.7
130.7

Max. Load Strain

MPa
%
78.087
5.105
78.126
5.157

Elastic Modulus
MPa
2196.456
2197.537

(Table 2.0: Experimental results)

Using the following experimental readings and comparing with known values for polymers:
Flexural Strength 78 MPa
Elastic Modulus, G 2.20 GPa

(Table 3.0: Flexural strength and Flexural Modulus of polymers)

15

(4.2) Material Determination

We find that the sample most closely resembles the material acrylonitrile butadiene styrene,
ABS. If an additional property were tested, material determination would have been more
accurate.
This material is mostly found in miscellaneous objects such as Lego blocks, computer
keyboards, power-tool housing. Its most used for its light weight and impact resistance.

(Figure 8.0) Sample shape before and after Lab Testing

16

DISCUSSION AND CONCLUSION

(5.0) Discussion
Since the experiment was manually operated, the operator has to stop the machine manually
when the strain is at 5%. This caused the difference in the strain reading above because test 2
runs minutely longer than test 1.
If given the opportunity to conduct a second property test, such as Brinell Hardness Test, a
more accurate determination of the polymer type would have been possible.

(6.0) Conclusion
In conclusion, the objectives of this sample testing have been reached. We were able to
determine two mechanical properties of the polymer given. We were able to determine the
flexural strength and the flexural modulus of the sample given by doing flexural test.
After the sample testing, we were able to recognize that the sample that was given to us is
acrylonitrile butadiene styrene, ABS which has the closest properties to our sample that was
tested and also from the graph obtained, we can conclude that the sample given to us is ductile
with a very low flexibility.

17

REFERENCES

1) ASTM D790-03, Standard Test Method Flexural Properties of Unreinforced and

Reinforced Plastics and Electrical Insulating Materials, ASTM International.
2) Dowling, N.E., Mechanical Behavior of Materials: Engineering Methods for
Deformation, Fracture and Fatigue, 2nd edition, 1999, Prentice Hall, ISBN-0-13010989-4.

3) Hibbleler, R.C., Mechanics of Materials, SI second edition, 2005, Prentice Hall, ISBN 013- 186-638-9.
4) Flexural Properties Testing. (n.d.). Retrieved July 24, 2016, from
http://www.intertek.com/polymers/testing/flexural-properties/
5) Gonzles, A., Testing of Plastics. Retrieved July 19, 2016, from
https://www.linkedin.com/pulse/testing-plastics-antonio-gonzles

6) Rogers, T., Everything You Need to Know About ABS Plastic. Retrieved July 26, 2016,
from http://www.creativemechanisms.com

18

APPENDICES

19

20

21

22

MINUTES OF
MEETINGS

23

24