TMM – WS 2011/12

Prof. Dr.-Ing. P. J. Mauk 07.03.2012

Ch. Overhagen, M.Sc.
Institute for Metallurgy and Metal Forming

Examination: Testing of Metallic Materials / WS 2011/12

Advice: Use a new page for every problem!

A minimum of 54 points is necessary for passing the exam!
Place your name and matricle number on top of page 2 !
Total: 136 points ; 4.0 = sufficient: 54 min. points ; 1.0 = excellent: 115 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 (25 Points):

At room temperature, a frictionless upsetting test is conducted on a metallic sample
of initial diameter d0 = 10 mm and initial height h0 = 20 mm. At a force of F = 380 kN,
a machine displacement of s = 16.0 mm is measured. The testing machine has an
elastic rigidity modulus of CM = 425 kN/mm.
a) Determine the engineering stress  for this case !
b) Calculate the plastic deformation of the sample and the elastic deformation of
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).

2. Problem (12 Points):

A fine grain construction steel with a mean grain size of 15 µm has a yield stress of
Rp0,2 = 300 MPa. At a mean grain size of 12 µm the yield stress will be 335 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 8 µm based on the data
given above ?

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

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TMM – WS 2011/12

Name:

Matricle Number:

3. Problem (15 Points):

The plot below shows the homogeneous elongation region of a stress-strain curve of
a tensile test on a severely prestrained rod ( 0  0.35 ) made from construction steel.
(Small interval on strain axis = 0.025 %, Small interval on stress axis = 20 N/mm²)

Solve the following tasks graphically:

a) Approximate Young’s Modulus E for this material from the measured data.
b) Find the engineering yield stress Rp0.2 at a plastic strain of 0.2 %.
c) Find the engineering yield stress Rp0.05 at a plastic strain of 0.05 %.

4. 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 ?

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5. Problem: (20 Points)

A tensile test on a sample with diameter d0 = 15 mm and a measuring length of
L0 = 85 mm results in a maximum force of Fmax = 151.3 kN. The elongation at
maximum force is a change in length of Δl = 10.35 mm. The specimen length after
fracture is 99.5 mm, the smallest necked diameter of the specimen is 7.6 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 45 kN, a change in length of 0.030 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

-0.006 mm is measured. Determine Poisson’s Ratio for this material.

6. Problem (15 Points):

A tensile test with a fine strain gauge measurement is conducted on a sample of
diameter d = 10 mm. The strain gauge has a maximum deviation of 0.001 mm; the
force measurement has a maximum deviation of 0.1 kN.
For the strain gauge, three measuring lengths are available.
Calculate the combined uncertainty resulting from the deviations in the measuring
quantities, which can be expected for the measurement of Young’s Modulus from this
tensile test. The sample is perfectly manufactured and aligned in the testing machine.

a) L0 = 12.5 mm; measured elongation: 0.01 mm; measured force: 13.195 kN

b) L0 = 25.0 mm; measured elongation: 0.01 mm; measured force: 6.597 kN
c) L0 = 50.0 mm; measured elongation: 0.01 mm; measured force: 3.299 kN

 E   E
2 2

Hint: Combined Uncertainty: E    F     s 
 F   s 
7. Problem (12 Points):
A flat tensile specimen with initial dimensions thickness s0 = 1.2 mm, measuring
length L0 = 100 mm and width w0 = 18 mm is being deformed in a testing machine for
a time of 60 seconds with a tool velocity of v = 0.2 mm/s in the homogeneous strain
region. After the deformation, the width was measured to be w1 = 16.8 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 = 0.10, a force of F1 = 10.0 kN is measured. At
an engineering strain of 2 = 0.12 the force is measured to be F2 = 10.3 kN.
Calculate the n-value !

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8. Problem (10 Points):

A hot rolled rod with initial diameter of d0 = 12 mm is investigated in tensile tests.
The general flow curve of the material is given by k f    1015  0.3756 .
The material shows no Bauschinger Effect.

The rod is stepwise prestrained and 4 samples are manufactured. The following table
shows the diameters of the prestrained samples and the maximum forces in the
tensile tests.

Sample Diameter Fmax [kN]

(prestained)
01 11.5 58.51
02 10.0 57.52
03 10.5 56.20
04 10.0 56.21

a) Calculate the initial true strains, yield stresses, tensile strengths and ratios
Rm/kf of the 4 samples.

b) What tensile forces would be measured at sample 01 and sample 04 at the

start of plastic yielding, if the tensile tests were carried out under a surrounding
radial pressure of p = - 50 MPa ? (use Tresca’s yield criterion)

9. Problem (15 Points):

N
A part is loaded swelling at a nominal stress of S  75 . The initial crack length
mm2
is a0 = 1.25 mm. The following data are given: m = 4 and the geometry factor
Y = 2.5 = 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 = 5.14 mm is
reached !

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