HST22 TORSION OF RODS AND TUBES Instruction Manual INSTRUCTION MANUAL HST22 Torsion of rods and Tubes HST22IM/E/001 Page 1 of 30HST22 TORSION OF RODS AND TUBES Instruction Manual LABORATORY TECHNIQUE Safety The principal hazards in using apparatus that demonstrates the static and dynamic performance of associated theorems and the assumptions involved are where rotary or linear motion occurs and where the handling of loose heavy items, for example weights, is part of the procedure. the Laboratory Of the loose items the heavier weights must be regarded as the most dangerous objects. Should one of these fall onto the feet of those around the apparatus the potential for damage is present. Hence it is recommended that cast iron weights be handled carefully and when moving and placing the heavier ones (say 10 N upward) ‘on load hangers this should be regarded as a two handed operation. It is surprisingly easy to spill a complete stack of weights off a hanger when adding a further one, In addition to weights there are some heavy parts that have to be interchanged during some experiments and a similar approach using two hands where required is, suggested, It may also be both sensible and necessary for two people to take part in changes to the apparatus. Success in the Laboratory ‘Work in the laboratory depends on understanding, observation and skill. In the first place a good understanding of the performance, and limitations, of experimental models is needed. To know about the theory involved is useful but not essential. In the second place keen observation leads to better results and avoidance of mechanical mistakes, Lastly, the way in which students handle the apparatus can influence the accuracy and speed of the work. To help students gain experience and improve their experimental technique a range of information is offered in the following notes. Bear in mind that in the world of real engineering itis often necessary to check the performance of new designs using the methods and instruments of laboratory experiments. Desian of Experimental Models The purpose of each experiment is to illustrate an item of structural theory, or to show how well simplifying assumptions in the applied mathematics correspond to actual behaviour. This often requires the model to exaggerate the behaviour of a real structure. In order to achieve specific objectives each experiment has a particular amangement best suited to the theoretical requirement. These arrangements of the apparatus are described in the Construction Appendix, where included, of each experimental Instruction Manual. Before starting an experiment students should read through the instruction Manual and be prepared to follow the recommended procedure. Increased deflections are usually achieved by using very flexible models. The stiffness depends on El or EA so a change of material from steel (E = 205 kNimm?) HST22/M/E/001 Page 3 of 30HST22 TORSION OF RODS AND TUBES Instruction Manual to aluminium (E about 1/3 E for steel) or a plastic (E about 1/80 E for steel) is a solution. The alternative is to use thin steel beams with a low J. One disadvantage experimentally is that friction in bearings may affect displacements and force measurements. The other is that large changes in dimension (geometry) of models must be accommodated if possible. Results can be improved by using stiffer models and larger loads, but this reduces visual effects such as curvature of beams. Sources of Resistance A knife-edge can simulate a frictionless pin or bearing, but horizontal and rotational movements demand ball bearings. These are packed with grease and fitted with shields to keep out dust and grit. Hence ball bearings have some torsional restraint, which affects forces in the order of magnitude 1 N. This shows up as a difference in readings for loading and unloading. Pin joints in trusses are also subject to friction, which increases in proportion to the loading, Repeatability of Readings The ability to obtain accurate and repeatable experimental results is generally a matter of care and technique. Of course it helps to know the sources of error and to recognise when the apparatus contributes to the variability of readings. Frictional variation can be minimised by using vibration. The extent of the friction can be observed by first increasing and then decreasing an applied load by hand to get the difference in readings. Tapping the frame on which the experiment is mounted will reduce the variation. Cast iron weights for loading must always be applied gently. A load suddenly added will instantaneously apply twice its static value, Although weights are hand finished there is a manufacturing tolerance of + 4%. This may affect linearity in experimental readings. HST22IM/E/001 Page 4 of 30HST22 TORSION OF RODS AND TUBES Instruction Manual TORSION of RODS and TUBES INTRODUCTION The elastic deflection and eventual failure of beams in bending is related to the behaviour of the beam material in direct tension and compression. However, there is. another way of distorting material that occurs when it is twisted. In the simplest case a length of round rod can be twisted about its longitudinal axis in such a way that no bending or direct stress is involved. This is called pure torsion. Torsion of shafts is very common in mechanical engineering where power transmission takes place. In most cases the shafts have a circular cross section which is sometimes hollow with a uniform wall thickness. It is evident from the theory of torsion that the material at the centre of a rod does not contribute much to the strength or resistance to elastic twisting, so there is considerable economy to be achieved in hollow members. In structural engineering torsion is less of a problem unless there is a special condition of loading. The traditional steel members used for building have an inherent safety against failure by twisting partly because of the high value of the modulus of torsional rigidity of steel and partly due to the way buildings are constructed. The replacement of steel by aluminium alloy brought with it a possibility of secondary compression failure due to a column twisting on its axis. As more plastics are used structurally their very low moduli of rigidity (compared with metals) makes distortion by twisting much more of a problem. This has led to the increasing use of hollow box sections to provide the maximum torsional stiffness. APPARATUS DESCRIPTION HST2UMIE/001 Page 5 of 30HST22 TORSION OF RODS AND TUBES Instruction Manual LOAD CELL HEAD TORSION VERNIER POINTER HEAD ‘SPECIMEN HST1 FRAME A torsion head with ball bearings to minimise friction is fitted with a three jaw chuck for gripping the specimens. Integral to this torsion head is a worm and wheel gear arrangement terminating in two small thumb knobs. The worm and wheel arrangement provide equal and opposite forces onto the torsion specimen, By rotating the torsion head thumb knobs, the specimen can be made to rotate about a centreline. This arrangement gives fine and accurate control of the direction and magnitude of the twist of the specimen. To anchor the other end of the torsion specimens a three jaw chuck is fitted to the test frame via a load cell head assembly. The chuck again runs in precision bearings and a lever arm protrudes at right angles from the end of the chuck shaft. This lever arm applies a force to a load cell mounted to the side of the HST1 Universal Frame and Stand (sold separately). The centre distance between the chuck shaft and the point of contact of the lever arm onto the load cell is 65mm. As the specimen is rotated by the torsion head, the lever arm applies a force to the load cell. This generates a signal from the load cell, which is fed directly into the HDA200 Interface (sold separately). The amount of twist from the torsion head is electronically fed into the HDA200 Interface also via an integral connector on the side of the torsion head. The set of specimens provided have ends machined with three flats at 120° spacing to improve the grip of the chucks and to reduce slippage. Details of the specimens are:- - Solid aluminium alloy @4.74mm rod ~- Aluminium tube @9.5mm outside diameter and @6.3mm inside diameter - Aluminium tube 9.5mm outside diameter and @6.3mm inside diameter, with longitudinal slit - Acrylic rod, @10mm diameter - Aluminium Square Hollow section 12.7 mm side and 1.63 mm wall thickness ‘Two angular deflection scales can be clamped in positions along the length of the specimen. Vernier pointers are gripped onto the specimens and run against the deflection scales to give an accurate angular movement reading. HST222/E/001 Page 6 of 30HST22 TORSION OF RODS AND TUBES Instruction Manual To help grip vernier pointers onto the specimens split collars in black plastic are used with the @9.5mm outside diameter specimens. White plastic split collars are used to clamp the 10mm diameter acrylic rod, The square specimen fits in the vernier Pointers without any bushes. The verniers give a direct reading to 0.1°, A lead is supplied to connect the torsion head output to the HDA200 Interface. The load call has an integral cable pre-wired. ‘The output from the load cell is fed into the HDA200 Interface. This reads the force being applied to the load cell during twisting of the specimen. Knowing that the lever arm contacts the load cell at a distance of 65mm from the specimen centreline, it is then possible to calculate the torque being applied. To measure the angle of twist of the specimen, two methods are employed; analogue and electronic. The analogue method requires the end user to record the angle of twist from the vernier pointer and deflection scale. The electronic method requires that the integral rotary transducer output is fed into the HDA200 unit. The cable to connect the rotary transducer to the HDA200 is supplied. pean oa SOON. a yan sg A (223 ee M HST22/M/E/001 Page 7 of 30H8T22 TORSION OF RODS AND TUBES Instruction Manual APPARATUS ASSEMBLY ‘The apparatus is shipped in a disassembled form. The key items within the assembly are as follows: Torsion head: THUMB KNOB y ‘SPECIMEN CHUCK IGLE OUTPUT CABLE. TO HDA200 : Pe Load cell Head Assembly: LOAD CELL Rea LEVER ARM ] SPECIMEN CHUCK HST22NWE/001 Page 8 of 30HST22 TORSION OF RODS AND TUBES Instruction Manual Angular Deflection Scale Assembly: ’ ‘HST22/M/E/001 Page 9 of 30HST22 TORSION OF RODS AND TUBES Instruction Manual Other items within the unit's assembly include: 1. 5 piece specimen set 2. Removable clamp bushes 3. Text book 4. 6mm AF hexagon wrench 5. Tape measure This experiment must be mounted within the HST1 Universal Frame and Stand (sold separately). It is assumed the end user has purchased and assembled this frame before commencing with the following procedure. The following steps should be taken fo mount the HST22 items within the HST frame ready for running the experiment 4. Remove all items from their respective packaging and discard the packaging responsibly. 2. Fit the torsion head into the working cavity of the HST1 frame, so that it sits approximately 100mm from the inner left edge of the left hand vertical: To fix the torsion head to the frame use the two aluminium anchor plates and MB x 50 socket head cap screws supplied. The anchor plates fit into the working gap of the frame. The torsion head has two anchor plates and screws ‘supplied. 3. Attach the load cell assembly to the right of the torsion head approximately ‘550mm. Again use the anchor plate, screws and 6mm A/F hexagon wrench supplied. The load cell should be facing you, and the chuck should be facing the torsion head. 4, Attach the load cell plate to the underneath of the lower members of the HST1 Frame. The 12 hole in the load cell plate must be protruding outside the edge of the HST‘ Frame. The load attaches to the plate, with the hexagon headed bolt sitting uppermost. The lever arm will rest on top of the hexagon nut when the test is underway HST22qW/E/001 Page 10 of 30HST22 TORSION OF RODS AND TUBES Instruction Manual 5. Fit both of the angular deflection scales to the frame with the numbers reading correctly when you are viewing them: 6. The vernier pointers slide over each specimen. However, each specimen has a different diameter and hence the reason why different coloured clamp bushes are supplied (2 x white and 2 x black). Depending on the specimen being tested the correct bush should be fitted prior to installing the specimen. ‘The @4.74mm specimen cannot have the vernier pointers fitted. Each vernier pointer has a letter added to it. These should be paired with the same lettered deflection scale. HST220M/E/001 Page 11 of 30HST22 TORSION OF RODS AND TUBES Instruction Manual 7. The specimens have profiled ends at both ends. This ensures accurate gripping of the specimens within the chucks and to reduce slippage. 8. With the vernier pointers fitted, slide one end of the specimen into the torsion head. Support the specimen whilst the chuck within the torsion head is being tightened. Ensure that the jaws of the chuck clamp down onto the profiles at the end of the specimen. Also ensure the labels on the vernier pointers are reading the correct orientation. Tighten fully the chuck using the chuck key supplied. Tighten the chuck in the 3 positions available. 9. Bring the load cell head towards the free end of the specimen. With the load cell head free, tighten the load cell head chuck onto the specimen again ensuring the profiles of the specimen are being clamped on. You will find that the chuck will need to be rotated to ensure correct alignment. This can either be done by hand OR by turning the thumbscrew which is mounted to the torsion head 10. Tighten down fully the load cell head, once the specimen has been correctly clamped at either end. 11. Move the load and load cell head so that the load cell is directly under the lever arm, Secure into place. 12. The vernier pointers can be set to the correct span by loosening the integral thumbscrew and sliding it into position. Once in position tighten the thumbscrew. 13. The deflection scales can be moved to the side of their respective vemier pointer by releasing the screw undemeath and sliding along. Once in position, secure the screw using the hexagon wrench provided, HST22/M/E/001 Page 12 of 30HST22 TORSION OF RODS AND TUBES Instruction Manual HDA200 INTERFACE CONNECTION 1. The load cell cables should have green connectors fitted, If not then the load cell should be wired exactly as shown below: Where: Green & blue (if supplied) = +BS (Positive Bridge Supply) Black & brown (if supplied) = -BS (Negative Bridge Supply) Red = +IP (Positive Input) White = -IP (Negative Input) If the additional blue and brown wires are not attached this will not affect the functionality of the load cel 2. These connectors fit into the HDA200 Interface. The load cell connects into ‘one of the force channels on the HDA200 Interface. The force channels are located on the left hand side of the HDA200 Interface, as shown below: USB Port Force 1 Angle 4 HST22/M/E/001 Page 13 0f 30HST22 TORSION OF RODS AND TUBES Instruction Manual 3. The HDA200 channels that have been set up for the experiment will have been indicated on the HDA200 Interface test sheet. If for any reason this is not available, then the load cell should be connected into the first socket to the right of the USB port (see image above and below). Channel 17 | ia (force 1) Angle channel 1 The cable for the angle output from the torsion head of the apparatus has three wires coming from it: Red wire = angle channel 1 socket with RED arrow (see above) Blue wire = angle channel 1 socket with BLUE arrow (see above) ‘Yellow wire = angle channel 1 socket with YELLOW arrow (see above) The connectors should have been factory fitted for the angle output cable, but if not the above detail will help with the wiring. One of the load cells connected into Force 1 channel of the HDA200 Interface is shown below: HST22/W/E/001 Page 14 of 30HST22 TORSION OF RODS AND TUBES: Instruction Manual 4. Should you wish to connect the load cell into another force channel or convert a strain channel into a force channel, then see the HDA200 Interface instruction manual. 5. Connect the HDA200 Interface to the power supply supplied; ensuring the correct plug adaptor is used for the country the HDA200 Interface is being used in, 6. When the power supply is turned on, the HDA200 Interface will show a screen as follows: 7. Press the green button next to the ‘No’ words at the next screen unless the channel configuration you wish for is not set up correctly. If this is the case, then consult the HDA200 Interface. 8. Press the green button next to the words ‘local’. HST22/M/E/001 Page 15 of 30H8T22 TORSION OF RODS AND TUBES Instruction Manual 9. After the ‘Local’ button has been pressed, the following screen will appear for 's short time. 10. The next screen to show will be the force channel(s) that have been factory set. This should be Force 1 for the HST4 experiment. If it is not then see the HDA200 Interface instruction manual for adjusting the channels being read and viewed. 11. The value on the screen of the HDA200 will require zeroing off (taring). To do this simply press the top green button for around 2-3 seconds, until the following message appears on the HDA200 display: HST22M/E/001 Page 16 of 30,HST22 TORSION OF RODS AND TUBES Instruction Manual 12. The value should now return to zero (or within +0.1N). If not simply tare the unit again. 13, The angle reading will not return to zero as this is factory set. 14, With the load cell and angle output connected to the HDA200 Interface the apparatus and the HDA200 Interface powered, the apparatus should now be ready for the first part of the experiment. HST22/W/E/001 mz Page 17 of 30 eHST22 TORSION OF RODS AND TUBES Instruction Manual EXPERIMENT OBJECTS 1 To investigate the torsional rigidity of solid and hollow circular rods. 2. To.compare the torsional efficiency of a hollow and split hollow section, 3. To study the behaviour of a hollow square section. PROCEDURE Part 1 Fit the solid aluminium @4.74mm specimen between the chucks of the torsion head and load cell head. Record the gauge length (distance between chucks for this specimen), The vernier pointers cannot be fitted to this specimen. Turn the thumb knob on the torsion head until the lever arm just rests on the load cell. The HDA200 interface display will show a change in force when the lever arm is touching on load cell. Check the angle value on the HDA200 interface is reading. Zero the HDA200 Interface and record the ‘no load’ force reading and angle reading into table 1 Gradually turn the thumb knob to increase the twist of the specimen. In increments of 1N (approximately), up to a maximum of 10N record the angle of twist from the HDA200 and record in table 1. Record these values in table 1 as shown below: Table 1 Twist/Torque of a solid aluminium rod Gauge tength mm Coad, F] Torque | HDA200] Actual] Actual Twist_| Twist_| Twist N | Nmm a a HST22/ME/001 Page 18 0f 30HST22 TORSION OF RODS AND TUBES Instruction Manual Part 2 Repeat the procedure for part 1 for the acrylic specimen but slide the vemier pointers onto the specimen, with their clamp bushes, before attaching between the chucks. DO NOT OVER TIGHTEN THE CHUCKS AS THIS COULD DAMAGE THE ENDS OF THE SOFT MATERIAL ACRYLIC. The angular deflection scales are clamped in position so that the scales are to the front of the frame with their vemiers just touching the scales. The verniers, with tan divisions equal to nine degrees on the quadrants, enable the angular rotation to be read to 0.1' Set the deflection scales 150mm apart. Set the verniers to 40° on each scale. Turn the torsion head until the lever arm just rests on the load cell and making sure there is a change in output of the force reading on the HDA200. Zero the HDA200 and record the vernier scale readings and ‘no load’ readings in table 2a. In increments of 1N, up to a maximum of 10N, twist the specimen using the thumb knobs on the torsion head and at every interval record the angle of twist from the HIDA200 into table 2 below. Also record the change in vernier readings for every 1N increment and record in table 2a also. Table 2a ‘Twist/Torque of a Perspex Rod Gauge length 150 mm "| HDAZ00] Actual] Actual] Vernier [ vemer) Load, F | Torque | Twist | Twist | Twist | a |B | als ‘ aa N Nmm | a Ed ee es Move the scales and verniers to increase the distance between them to 300 mm, and repeat the above loadings and readings, using Table 2b. Table 2b Twist/Torque of a Perspex Rod Gauge length 300 mm ~[ADAZ00] Actual | Actual Load, F | Torque | Twist | Twist | Twist N Nmm [= = | Radians HST22/M/E/001 Page 19 of 30,HST22 TORSION OF RODS AND TUBES Instruction Manual Part3 Replace the acrylic specimen with the aluminium tube and reattach the vernier pointers with their clamp bushes. Record the gauge length. Use the scales 300 mm apart with the verniers starting at 40°, ‘Twist the lever arm onto the load cell until a reading from the HDA200 is seen to change. Zero the HDA200 and record the ‘no load’ readings for force and angle twist from the HDA200 and verniers scales into table 3a. Apply load in 1N increment, up to a maximum of 10N, reading and record the angular deflections from the verniers and scales and the angle output from the HDA200 in table 3a. Table 3a ‘Twist/Torque of a Aluminium Tube Gauge length 300 mm HDA200] Actual | Actual | Vernier | Vemier | BA Load,F | Torque | Twist | Twist | Twist A eg) | @ea) N ‘Nmm cet |e Radians: Part 4 Take the split tube specimen next, ensuring the vernier pointers and clamp bushes are fitted in the correct orientation. Set the vernier scales and pointers to 300mm. gauge length. Zero the HDA200 and record the vernier pointer readings, HDA200 angle output and ‘no load’ readings into table 4. Apply 1IN increments up to a maximum of 16N, reading the angular deflections from the verniers and HDA200 and recording in table 4 Table 4 ‘Twist/Torque of a split tube Gauge length 300 mm HDA200 | Actual |“ Actual | Vemier | Vernier Load, F | Torque | Twist | Twist | Twist | A Bo (eg) | Weg) | N Nm EB * | Radian Part Finally, take the hollow square section, making sure that the two vernier arms without collars are threaded on before inserting the specimen in the chucks. The specimen, should have the short stub end to the left with one vernier 20 mm from the shoulder. Set the deflection scales 300 mm apart and set the verniers to 40° on each quadrant. Ensure the lever arm is resting on the load cell and there is a change in the HDA200 output when doing this. Zero the HDA200 and record the ‘no load’ readings of force, vernier scales and HDA200 angle reading into table 5 HST22M/E1001 Page 20 of 30HST22 TORSION OF RODS AND TUBES Instruction Manual Apply 2N increments up to a maximum of 20N to the specimen, reading and recording the HDA200 angle reading and vernier scale deflections for each loading into table 6. Table 5 Twist Torque of a Hollow square section ‘Gauge length 300 mm HDA200 | “Actual | Actual | Vemier | Vemier | B=A Load,F | Torque | Twist | Twist Twist A See (Deg) | (eg) | (ea) N [Nm [= [+ _[Radiens | RESULTS PROCESSING Using the table for each part derive the angular twist over the gauge length between the pointers or chucks by taking the differences of the angular deflections. Convert the actual angle of twist into radians. For part 1, part 2 and part 3 plot the angular twist (radians) against the applied torque for the gauge length of the specimen between the chucks. Draw in the best fit straight lines and calculate their slopes. Use the results to derive the modulus of rigidity, G for the aluminium solid rod and acrylic rods from the equation: a aa 1 where TI@ = slope of graph, but 9 in radians J = torsion constant xo/32 L = gauge length Draw a graph for the results of part 4 for the aluminium tube with a slit in it. Draw a graph for the results of part 5, for the hollow square section, Use the modulus of rigidity value for the aluminium rod of part 1, rearrange equation 1 above to calculate the apparent “J' value for the aluminium split tube. Compare this experimental torsion constant with the theoretical value given by nye BaP a as where d = mean diameter of tube t = wall thickness ‘Again using the value of G for the solid aluminium rod of part 1, rearrange equation 1 to calculate the value for /’ of the hollow square tube. Compare this with the theoretical value vo =st HST22/M/E/001 Page 21 of 30HST22 TORSION OF RODS AND TUBES Instruction Manual é @ = external size of square tube 6b —-=internal size OBSERVATIONS Given that we are dealing with elastic torsion the graphs should be linear. Did the results agree with this (particularly those for the acrylic)? The handbook values for the moduli of rigidity, G are 26200 N/mm? for aluminium alloy and 1200 N/mm? for acrylic. Comment on the experimental comparisons. Using a maximum shear stress q = 100 N/mm? calculate the maximum torque for the solid and tubular aluminium alloy specimens. Then calculate the torque carried per mmm? of cross section and comment on this aspect of economy. What is the disadvantage, if any? ‘The slit in the tube specimen was made with a 1 mm saw. Note the great change in torsional stiffness. The shear stress in such a case is given by aT ona CONCLUSIONS Does the simple theory of torsion apply to circular section rods and tubes? What is the optimum way of designing for torsion in the following cases: * Maximum torque within a set diameter, * Lightest member for a given shear stress. + Allarge rotation (for example a torsional spring). HST22/M/E/001 Page 22 of 30HST22 TORSION OF RODS AND TUBES Instruction Manual MAINTENAI! P.A.Hilton Ltd equipment needs little maintenance since so far as possible materials and finishes are corrosion proof and long lasting. Replacement and Spares These can be ordered using the experiment and part number plus a description. Test Specimens Most of the experiments are within the linear elastic range of the test specimen and materials used, CONTACT DETAILS Address: P.AHilton Ltd King’s Somborne Stockbridge Hampshire, $020 6PX, United Kingdom Telephone: +44 (0) 1794 388382 ax: +44 (0) 1794 388129 Web Sites: httow/Awww.hi-techedu.com/ or htto://www.p-a-hilton.co.uk HST22/M/E/001 Page 29 of 30,