TMM – SS 2011

Prof. Dr.-Ing. P. J. Mauk 17.08.2011

Institute for Metallurgy and Metal Forming

Examination: Testing of Metallic Materials / SS 2011

Advice: Use a new page for every problem!

A minimum of 56 points is necessary for passing the exam!
Total: 142 points ; 4.0 = sufficient: 56 min. points ; 1.0 = excellent: 120 min. points

Engineering Strain : ENG True Strain : TRUE

Engineering Stress : ENG True Stress : TRUE
F F
ENG  TRUE 
A0 A
dl dl
dENG  dTRUE 
l0 l

1. Problem: (20 Points)

A tensile test on a rod with diameter d0 = 5.5 mm and free measuring length of L0 =
200 mm gives a maximum force of 15 kN. The force at fracture was 7 kN. The
elongation at maximum force is a change in length of Δl = 32.5 mm. The specimen
length after fracture is 250.6 mm, the smallest necked diameter of the specimen is
2.9 mm.

a) Find the engineering stress and strain and the true stress and strain at
maximum force.

b) Find the local true stress and true strain at the smallest necked diameter at
fracture.

c) Calculate the fracture strain in % and the reduction of area in %.

d) In the elastic region at a force of 5 kN, a change of length of 0.025 mm is

measured with an extensometer, having an initial gauge length of l0,extensometer = 25
mm. Calculate Young´s modulus of this material!

e) For the case according to d) a change in diameter of the sample of

-0.0017 mm is measured. Determine Poisson’s ratio for this material.

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2. Problem (12 Points):

Describe the following sheet metal tests in your own words:

a) Erichsen Test
b) Up-and-down bending test
c) Nakazima Test
d) Swift Cupping Test

What data is found in each of those test procedures ?

3. Problem (12 Points):

A fine grain construction steel with a mean grain size of 25 µm has a yield stress of
Rp0,2 = 230 MPa. At a mean grain size of 20 µm the yield stress will be 270 MPa.

a) Determine from these data the constants of the Hall-Petch-equation

1

Rp0,2  F  i  k y  d 2

b) What yield stress can be expected at a grain size of 15 µm based on the data
given above ?

c) Describe the influence of grain size on yield stress by means of the Hall-Patch-
equation!

4. Problem (25 Points):

At room temperature, a frictionless upsetting test is conducted on a metallic sample
of initial diameter d0 = 32 mm and initial height h0 = 60 mm. At a force of F = 1200 kN
a machine displacement of s = 20.3 mm is measured. The testing machine has an
elastic modulus of CM = 375 kN/mm.
a) Determine the engineering stress  for this case !
b) Calculate the plastic deformation of the sample and the elastic deformation on
the machine (elastic sample deformation can be neglected).
c) Calculate the diameter of the sample at that time.
d) Determine the engineering strain h.
e) Calculate the true strain and true stress (flow stress).

5. Problem (12 Points):

A tensile test on a steel material with initial diameter d0 = 15 mm gives a

homogeneous strain of 20 % and a flow curve of k f  600  0,16 for   0.05 .

a) Calculate the tensile strength Rm !

b) Calculate the maximum force in the test in kN and the true stress at maximum
force !
dTRUE
c) Calculate the derivative at maximum force !
dTRUE

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6. Problem (10 Points):

Define the following concepts in your own words:

a) Flow Curve
b) Tensile Strength
c) Deep Drawing
d) J-Integral
e) n-value

7. Problem (12 Points):

A flat tensile specimen with initial dimensions thickness s0 = 2.5 mm, measuring
length L0 = 125 mm and width w0 = 25 mm is being deformed in a testing machine for

a time of 10 seconds with a constant strain rate of   1.5  102 s1 in the
homogeneous strain region. After the deformation, the width was measured to be w1
= 22.9 mm.

a) Calculate the longitudinal strain l and the measuring length of the deformed
sample.
b) Calculate the r-value.
c) Calculate the final thickness s1.
d) At an engineering strain of 1 = 0.05, a force of F1 = 14 kN is measured. At an
engineering strain of 2 = 0.1 the force is measured to be F2 = 17 kN.
Calculate the n-value !

8. Problem (12 Points):

Notched bars with circular cross sections (see attached drawing) are subjected to
tensile loading. The flow curve of the sample material shall be estimated to
k f  TRUE   835  0.2513 . At fracture, the following tensile forces and notch diameters
have been measured:

Smallest Force at
necked fracture
diameter [kN]
[mm]
Deep Vee Notch 7.40 31.70
Rectangular Groove Notch 5.80 31.60
R4 Notch 6.10 31.00

a) Find the tensile stresses TRUE for the three samples at fracture (mean value
along the cross section).
b) Calculate the acting radial stresses at fracture acc. to Tresca’s criterion of
yielding, if you assume the axial and radial directions to be principal directions.

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9. Problem (12 Points):

A specimen made from sheet material St1403 with sheet thickness h = 1 mm shall be
deformed by combined deep drawing and stretch drawing. The forming limit curve
(FLC) for this material is described by the following second-order polynomial:
1  2   1.518  22  0.168  2  0.711.

a) Calculate the diameters of a mesh circle in both principal strain directions of initial
diameter d1,0 = d2,0 = 5 mm after each of the three forming steps (see enclosed
strain path)
b) Calculate the respective sheet thickness after each deformation step.
c) Find the major strain and minor strain and the mesh circle diameters at fracture
of the sheet metal, if the forming procedure is continued with pure deep drawing
in step 4.
d) Calculate the equivalent deformation φeq acc. to v. Mises and the flow stress
after forming step 3, if the material has a n-value of 0.3639 and a flow stress of
820 N/mm² at φeq = 1.

10. Problem (15 Points):

N
A part is loaded swelling at a nominal stress of S  35 . The initial crack length
mm2
is a0 = 1.25 mm. The following data are given: m = 4 and the geometry factor
Y = 2.63 = const.

REF m
da  da   K 
The Paris equation is valid in the form   .
dn  dn  REF 
 K 
REF
 da 
The reference quantities shall be taken as    1 103 mm and
 dn 
K REF
 K aa0 .

Calculate the number of load cycles, until a critical crack length of ac = 11.50 mm is
reached !

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Attachments

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