Andrew Kerns

Section 6
Table D
5/1/17

Homework 8
Part A:

Part B:

When looking at the two types of tests there are advantages and disadvantages for each.
For the axial push-pull test it is relatively accurate. The test itself is able to be done rather
quickly and allows for the attachment of an extensometer to give more accuracy. The
disadvantage of this test is that upon failure we are no longer able to use the test subject because
of its failure. The machine itself can go through some deflection in testing that can alter some of
the data collection. The test subject needs to be thin and polished in order to limit premature
failure from cracks or scratches. Luckily with the minimum stress being zero we are able to use
this test. If it was not then we would have to look elsewhere because of the test always reaching a
zero force at some point in the vertical push-pull. For the four-point bending test we are able to
not worry about the sample being a thin polished sample, we can have a thicker part. If no
deformation occurs, which is a possibility, then the material can be reused for another test which
can be helpful to see if the results are repeatable. There are still disadvantages to this test style.
Like the previous test we have to have the minimum stress be zero. Also we have to have the
values collected must be reduced by ten percent to compare to the previous test. We must do this
because of the effects of bending-stress gradients, which occur because of the moments on the
supports from the load being applied perpendicularly.
When seeing the advantages and disadvantages from the two tests and from the amount
of cycles I would need to use, I would go with the axial push-pull method. A heat treated sample
of 2024-T3 aluminum with an ultimate tensile strength of 70,000 psi is to be tested for its
strength. It will fail in released tension when a cyclic stress is applied cycling between 0 and
45,000psi. The predicted failure mode for this sample will be fatigue and not plastic deformation.
Testing will occur on a dog bone sample with a cross sectional area of .01 in3 and a gage length
of 2in (Figure 1). The thickness is 1/32 in and the width is 0.32in. This test will be tested on the
Instron machine. The load of the Instron machine will oscillate between 0 and 450lbs in order to
provide the stresses between 0 and 45,000 psi. A small sample was used in order to reach a force
from 45,000psi that was in the 1124lbs the Instron could provide. In order to calculate the cycle
time and run time first it was confirmed that the material would not yield by finding eq-CR and
confirming that it was less than the yield stress, which it was. The deflection was then found
using the moment of inertia for the rectangular cross section and the deflection equation as seen
on the attached sheet.
In order to conduct this experiment more quickly a higher stress could be also be used in
order to reach failure in less cycles. This is ideal for a lab setting where the test should be
completed in the period. To run with a higher stress over a shorter amount of cycles the S-N
curve with knockdowns is referenced and simply taken from a different point. The limitation
here is the Instron itself that can only provide up to about 1124 lbs of tensile force. If 1124lbs
were used that would lead to an alternating stress of 60,000psi and would result in a failure after
approximately 104.1 =12,589 cycles. At .621 seconds per cycle with a total distance of
.414in/cycle this would take 2.17 hours for failure which is much faster than waiting over 28.82
days.
Setup Summary:
Max load = 450lbs
Min load= 0lbs
Hard stops: 36in, 18in
Speed: 40in/min
Moves approximately 0.166 in/cycle
Machine Speed: 40in/min
Cycle time: 0.249 sec/cycle
Expected runtime: 28.82 days