ME374: Manufacturing Process Lab
Compression Test Experiment
Prateek Jajodia (180100087): Group 9
Date: 09/01/2022
Aim
Determination of plastic flow properties of Aluminium under varying friction conditions in a
uniaxial compression test.
Apparatus
Universal Testing Machine (UTM) (Tinius Olsen make, Model H50K), vernier calipers, five
aluminum samples of the same diameter but different heights, grease
Theory
The compression test is used to determine the behavior of materials under compressive
loads. For the initial elastic deformation of the specimen, the stress-strain relationship is
governed by Hooke’s Law. Just like the stress-strain relationship for elastic deformation is
governed by Hooke’s law, the power curve relation deals with the relationship in the plastic
deformation zone. We use the curve along with the following relations to obtain the
coefficients K and n.
The slope and the intercept of the log(σ)-log(ε) plot gives us the values of K and n, as
log(σ) = log(K) + n*log(ε).
Friction at the interface between the specimen and the platens complicates the stress rate
and results in barrelling. The friction tends to prevent the radial expansion of the material in
contact with the platens. This creates a dead-metal zone at the top and bottom. These end
effects cause non-uniform stresses and strains. We use grease to ensure uniformity among
the various samples. We can relate the coefficient of friction and flow stress using the
equations from above. With decreasing coefficient of friction, the flow stress increases.
For the Cooke and Larke method, we vary the height of the samples while keeping the
diameter constant. We use it to study the effect of the d/h ratio on friction and consequently
obtain K and n using the graphs.
Working Formulae
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Experimental Procedure
1) The dimensions of the test piece are measured at 3 different places along its
height/length to determine the average cross-sectional area.
2) The ends of the specimen should be in a plane. For that, the ends are tested on a
bearing plate.
3) The specimen is placed centrally between the two compression plates. This is done
by ensuring that the center of the moving head is vertically above the center of the
specimen.
4) Load is applied to the specimen by moving the movable head.
5) The load and the corresponding contraction are measured at different intervals.
6) Load is applied until the specimen deforms to 60% of its initial height.
Observations
Sample Material: Aluminium
Specimen dimensions:
1) Heights H0 = 11mm
2) Diameter D0 = 10 mm
Excel sheet with name G9 11 is attached
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Assignments
1) Engineering stress vs Engineering strain graph.
2) Calculation of Modulus of Elasticity using the testing condition and its comparison with
experimental values
The least-squares line fit to the elastic region of the graph is plotted.
Observed Modulus of Elasticity = 1326 MPa = 1.326 GPa
Theoretical Modulus of Elasticity = 69 GPa
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Error in Measurement of Modulus of Elasticity= (|69-1.326| / 69) x100% = 98.07%
3) Location of the Yield point in Engineering Stress Strain Curve.
The intersection of both Engineering Stress curve and the 0.2% offset line gives the
location of Yield Point.
Observed Yield Point = 93.28 MPa
Theoretical Yield Point = 241 MPa (for 6061 Aluminium)
Error in Measurement of Yield Point = (|93.28-241| / 241) x100% = 61.294%
4) True stress vs True strain graph.
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5) log(σ)-log(ε) plot followed by determination of values of K and n.
A least-squares line is also fit to the plastic region of the graph.
We obtain log(σ) = 20.5 + 0.887*log(ε). Comparing with the equation,
log(σ) = log(K) + n*log(ε)
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Thus K = 799.902 MPa, n = 0.887
From the excel sheet the value of σmax=418.8726604 MPa
So Using this σmax and n
σavg= 418.8726604/(1+0.887) = 221.978092 MPa
6)True stress vs True Strain at different friction conditions (Here plotted wrt h)
since for some sheets, friction was not calculated
Conclusions
● Sample breakage happens at a much lesser force in the case of tensile than that of
the compression experiment.
● Strain produced in compression is comparably smaller than that of tensile pulling for
the same value of stress, which shows that Young’s modulus of tensile pulling is
greater than that of compression.
● The value of friction is negative in initial rows as friction is more evident in the plastic
region and imposing friction in the plastic region led to negative values of friction in
initial rows.
● The phenomenon of barrelling is also unique to compression testing.
Sources of Error
● Parallax errors in the measurement of the dimension of the specimen before and
after the test.
● Calibration errors in the software and machine used.
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● The best-fit curve and selection of appropriate elastic regions are all approximations,
thus are prone to errors.
● Manufacturing errors in the specimen may cause it to not get compressed in axially
straight
● Uneven deformation in the specimen can take place due to axial misalignment, this
may happen if the specimen isn’t placed at the exact center.
