Laboratory Hand Book Lab1 25Aug

Mechanical Engineering

Laboratory Investigation I

Hand Book

SEGi University

[SEGi University]

TABLE OF CONTENTS

1.0 Introduction (Flow Chart)

2.0 Safety

3.0 Laboratory Report

3.1 Writing Skill

3.2 Template

4.0 Marking Scheme

5.0 Penalties

5.1 Punctuality

5.2 Late Submission Penalty

6.0 List of Experiments

7.0 Lab manuals

8.0 Hand book for Student

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http://www.segi.edu.my/

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The objective of this manual is to introduce the basic principles and methods of

experimental engineering to the lecturer who is allocated to teach Lab Investigation I in

Mechanical Engineering Department.

This section consists of three flow charts that indicate the procedures to conduct lab

investigations.

Figure 1.1shows the sequence of proceduresto betaken if a lecturer is assigned to teach

Lab Investigations I.

Figure 1.2shows the organisation chart in Mechanical Engineering Department which

will assist the assigned lecturer to acquire relevant theory and lab skills according to their

disciplines.

Figure 1.3indicates the activities which are needed to be performedin the first lesson of

Lab Investigations. As an introductory class, regulation of lab, list of experiment/syllabus,

report writing skill and template, marking schemeandlate submission penalty has to be clearly

explained to students.

Figure 1.4explains the procedures of activities during experiment. Lecturer has to ensure

the students are wellprepared and have satisfactory knowledge of the expected task in the

laboratory.

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Figure 1.1 Actions Taken if Allocated to Teach Lab Investigation I

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Allocated to teach lab investigations

Get the list of experiments

Study the relevant lab manual

Contact person-in-charge for relevant discipline(refer to Figure 1.2)

Test run the lab before conducting it


Figure 1.2 Organisation Chart in Mechanical Engineering

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Heads of Lab

Solid Mechanics

Dr. Chia Chee Ming

Fluid Mechanics

Ir. Santha

Control & Automation

Mr. Patrick Teo

CAE & Project

Mr. Anthony Leong

Thermodynamics

Ir. Santha

Manufacturing & Materials

Mr. Chay Yit Sun

Design

Mr. Endra Sujatmika

Lab Investigations

Dr. Lai MK

Lab Executive and Officers

Mr. Teoh Chee Ming

Mr. Ahmad Fauze

Ms. Naslina


Figure 1.3 Activities in First Lesson of Lab Investigations I

Introduction (refer to Section 8)

Distribute list of experiment (refer to Section 6)

Distribute lab manual (refer to Section 7)

Show the lab report format (refer to Section 3)

Review lab report writing skill (refer to Section 3)

Explain marking scheme (refer to Section 4)

Explain the penalty for being late late to class and report late submission (refer to Section 5)

Inform students to buy lab coat (refer to Mr. Teoh)

Inform students in advance about the next lab

Figure 1.4 Activities during Conducting Experiment

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Take students' attandance

Check students' dress code

Brief experimental method and safety procedures

Supervise students to conduct the experiment (observe students' performance and evaluate with Rubric 2)

Discuss on the obtained results

Inform students in advance about the next lab


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Safety is of the most importance in the laboratory. Students will be working with hydraulic machinery

powerful enough to pull apart thick steel rod, at temperatures high enough to melt metallic alloys, at

voltages large enough to induce dielectric breakdown in insulators, and frequently with hazardous

chemicals dangerous enough to suffocate and/or burn human body instantly. If students have any

doubts and questions about safety, immediately stop any experiments and consult Teaching

Assistants/Coordinators. In order to avoid or at least minimize the risk of an accident the followings

are requested. Students not complying with these simple rules will be asked to leave the session.

(1) Know where the fire extinguisher is located in the laboratory.

(2) Must wear shoes.

(3) Do not wear loose clothing.

(4) Long hair should be tied behind the head.

(5) Safety goggles must be worn around testing equipment, rotating machinery,and

chemicals.

(6) Do not consume food or drink in the laboratory.

(7) All experiment must be performed within the allocated time. Students are not allowed to

work in the laboratory without proper supervision.

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3.1 Writing Skill

Each student is required to prepare a written report at the conclusion of every experiment. The

reports must always be brief, but yet provide sufficient information to convey to the reader that

the student understood the principles and techniques involved. The reports for this course should

never exceed 5-10 equivalent typed pages. Note that the largest percent of the student’s final

grade will be determined by the report of each laboratory experiment.

A plagiarized report (whether in part or in full) including copying from other sources,

from reports prepared by other groups, including another student in particular, will not be

allowed and will result in a zero grade. All reports MUST be handed in to the Teaching Assistant

in charge by the days of the week following the experiments. These reports should conform to

acceptable standards of report writing. The type of informationin reports will vary from one

experiment to another, but the reporting style should always state the purpose, background,

technique, and results as clearly as possible. The reports should always contain a cover page,

short abstract, brief introduction, main body, and summary/conclusions.

(1) Cover sheet

(2) Abstract

(3) Objective

(4) Introduction

(5) Apparatus

(6) Experiment procedure

(7) Results

(8) Discussion

(9) Conclusions

(10) References

(11) Appendices

All reports should be written up in the way used in scientific literature. A good lab report

does more than present data; it demonstrates the writer's comprehension of the concepts behind

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the data. Merely recording the expected and observed results is not sufficient; studentsshould

also identify how and why differences occurred, explain how they affected the experiment, and

shows their understanding of the principles the experiment was designed to examine. Bear in

mind that a format, however helpful, cannot replace clear thinking and organized writing.

Students still need to organize their ideas carefully and express them coherently.

A typical format for laboratory reports is given below:

1. The Title Page

The experimental title needs to contain the name of the experiment, the names of lab

partners/group, and the date of submission, name of marker, name of college and the institution.

Titles should be straightforward, informative, and less than ten words.

2. The Abstract/ Summary

A well written abstract summarizes four essential aspects of the report: the purpose of the

experiment (sometimes expressed as the purpose of the report), key findings, significance and

major conclusions. The abstract often also includes a brief reference to theory or methodology.

The information should clearly enable readers to decide whether they need to read your whole

report. The abstract should be one paragraph of 100-200 words.

3. Objective

Note that this is brief but clear and unambiguous. State the objective of the report clearly and

concisely, in one or two sentences.

4. The Introduction/ Theoretical Background

This is to place the work in the perspective of prior work including key literature survey. It states

the objective of the experiment and provides the reader with background to the experiment. A

good introduction also provides whatever background theory, previous research, or formulas the

reader needs to know. Usually, an instructor does not want you to repeat the lab manual, but to

show your own comprehension of the problem.

5. Apparatus

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List down the experimental materials or equipment.

6. Experimental Methods and Materials (or Equipment)

It is a record of how experiment was carried out. Use past tense and it should be impersonal.It

can usually be a simple list, but make sure it is accurate and complete. In some cases, you can

simply direct the reader to a lab manual or standard procedure. Do not copy from the handbook,

which, in any case, is not an account of the method, but a set of instructions.

7. Results and Analysis

This should include a complete listing of your experimental readings, any data manipulation,

required graphs, etc. Calculations, tables and figures usually dominate results. An important

strategy for making your results effective is to draw the reader's attention to them with a sentence

or two, so the reader has a focus when reading the graph.

Tables:

All significant results have to be stated explicitly. All columns and axes should be labeled with

the parameter name and its units.

Sample Calculation

It allows the reader to find out what is going on. The sample calculation will be followed by a

table of calculated results.More calculations can be included in report such as the slope of the

graph.

Graphs

Graphics need to be clear, easily read, and well labeled. Each has a title. The x and y axes are

clearly defined and labeled.

8. Discussion

This is the most important and crucial part of your report, because here, you show that you

understand the experiment beyond the simple level of completing it. Explain. Analyze. Interpret.

Some people like to think of this as the "subjective" part of the report. By that, they mean this is

what is not readily observable. You should not confined yourself just to these points, but

consider other aspects of the experiment.Discuss possible error and improvements. Should I have

discussed the measurement technique? How does my experimental result compare to the

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theoretical one? Does my result have any meaning in real life problems? If you make a

statement, you must be able to justify it in the rest of the report.

9. Conclusions

It is a brief statement to conclude your work. Your conclusion should briefly answer the

objective. Do not introduce any new material here; any conclusions must refer to material that

already discussed in the earlier report.

10. References

Any reference used must be mentioned in the main report and as part of a complete list at the end

of the reports. The reference list should give the author, the title of the publication and the date of

publication.

11. Appendix

Contains information necessary to the report but not important enough to include in the main

body; examples may include sample calculations, mathematical derivations and lemmas, error

analysis and data tabulation. Your suggestions on how the experiment might be modified to

improve the clarity of illustration of principles, the functionality of the experiments are always

welcome. You may include your feedback in the Appendices part of the report.

3.2 Report Template

This section consists of report writing template. A softcopy of report template should be

provided to students.

Font format for the lab report:

Font type: Times New Roman

Font size: 12

Font colour: Black

Spacing: Line spacing 1.5, before and after 0 pt

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[Mechanical Engineering Laboratory #]

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EXPERIMENT TITLE

Candidate’s Name:

Student ID:

Group Member’s Name:

Lecturer/ Supervisor:

Date of Experiment:

Date of Submission:

SEGi University

[SEGi University]


1. Abstract

2. Objective(s)

3. Introduction/ Theoretical Background

3.1. ABCDEF

Abc….

3.2. ABCDEFG

Xyz…

3.3. ……..

4. Apparatus

5. Experimental Method

5.1. Cautions

5.2. Method/steps

6. Results and Analysis

6.1. Pressure versus flow rate graph

6.2. Flow rates versus coefficient

6.3. ….

7. Discussion

7.1. …….

7.2. …..

8. Conclusion

Xxx…

9. References ( Following Havard Referencing)

1. Long, PE (ed.) 1991, A collection of current views on nuclear safety, Penguin, Harmondsworth.

2. Baron, D. P., 2008. Business and the organisation. Chester: Pearson.

3. Allouche, J. ed., 2006. Corporate social resposibility, Volume 1: concepts,accountability and reporting. Basingstoke: Palgrave Macmillan.

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This section prepares the marking scheme for student’s report, oral presentation performance and

their lab practical performance.

Student’s lab report is evaluated by using Rubric 1; student’s oral presentation is

evaluated by using Rubric 2; student’s lab practical performance is evaluated by using Rubric 3.

Remember to inform your students about the plagiarism will cause a 0% grade for their report.

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Rubric 1: Lab Report Marking Scheme

NoEvaluated

ItemsWeight Factor

MarkStudent

performance0 2 4 6 8 10

1General Layout

0.05 Does not follow guidelines.

Follows guidelines poorly.

Follows guidelines satisfactorily

Follows guidelines well

Follows guidelines extremely well

2 Title 0.05Not indicated.

Does not follow guidelines.

Topic is indicated poorly.

Topic is indicated satisfactorily

Topic is indicated well.

Topic is indicated extremely well.

3Abstract/ Summary

0.1

No summation is provided.

Summation is incomplete.

Poor summation.

Satisfactorily summation.

Good summation.

Very good summation.

4Introduction/ Background

0.2

Neither purpose nor scope is provided.

Purpose and scope are incomplete.

Purpose and scope are defined poorly. Background information provided is irrelevant.

Purpose and scope are defined satisfactorily. Provide background without context.

Purpose and scope are defined well. Provide adequate background and context.

Purpose and scope are defined extremely well. Thorough background and context.

5Experimental Procedure

0.1

No procedure has been provided.

Not written in past tense. Steps are illogical

Not written in past tense. Missing key steps.

Written in past tense. Missing key steps.

Written in past tense. Missing minor steps.

Written in past tense. Experimental details are comprehensive.

6

Results: Figures, graphs, tables, etc

0.2No Results have been provided.

Disorganised presentation of data. Missing essential support data.

Disorganised presentation of data. Missing essential support data.

Data is organised well. Missing some major support data.

Data is organised well. Missing some minor support data.

Exemplary presentation of supporting data. No format errors.

Information Paragraphs

Paragraphs are relevant

Paragraphs are relevant


Comments:____________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

____________

Important Notes:

Plagiarism – Plagiarism is a form of cheating. Do not use someone else’s ideas or words and

submit them as your own. 0% grade for plagiarising (even copying your friend’s work)

Rubric 2: Lab Practical– Marking Scheme

NoEvaluated

ItemsWeight Factor

Mark

0 1 2 3

1Attendance and promptness

0.1

Late for 21 mins and above or absent w/o reason.

Late for 20 mins Late for 10 mins Punctual

2

Carry out experiments by following steps given in the instruction sheets.

0.2

Does not bring lab manual during the experiment.

Do bring lab manual but do not use it during the experiment.

Do bring lab manual and use it during the experiment.

Do bring lab manual, have read it beforehand and use it fully during the experiment.

3Comply with safety procedures

0.2Not comply with safety procedure at

Do not dress proper for lab but often comply with the

Dressed proper for lab and follow safety procedures

Dress proper for lab and is fully complied with safe procedures

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in workshops and laboratories.

all. Does not dress proper for lab.

other safety procedures.

most of the time.in laboratories or workshop.

4Ability to work in group

0.2Extremely difficult to work with.

Often hindered group progress but occasionally promoted progress.

Sometimes hindered group progress.

Always had a cooperative attitude.

5Analysis of data

0.3

All data collected are wrong due to the misunderstanding of experimental method.

Data collecting method is not completely accurate and there are a number if error in the data.

Data collecting method is correct and data are mostly accurate.

Able to use the correct method to collect data, recognize human error or technical error (if any) and corrected them on the spot. Data collected are mostly or all correct.

Comments:____________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

____________

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Rubric 3: Lab PresentationEvaluation Form

NoEvaluated

ItemsWeight Factor

MarkStudent

performance0 2 4 6 8 10

1Title &

Objectives0.05

Neither purpose nor

scope is provided.

Purpose and scope are

incomplete.

Purpose and scope are defined poorly.

Topic is indicated

satisfactorily. Purpose and

scope are defined satisfactorily.

Purpose and scope are

defined well. Topic is

indicated well.

Purpose and scope are defined

extremely well. Topic is indicated extremely well.

2Abstract/ Summary

0.05No

summation is provided.

Summation is incomplete.

Poor summation.

Satisfactorily summation.

Good summation.

Very good summation.

3Introduction/ Background

0.1

No background

information is provided.

Provided background information

without context is irrelevant.

Background information provided is irrelevant.

Provide background

without context.

Provide adequate

background and context.

Thorough background and

context.

4Experimental Procedure

0.1No procedure has been provided.

Not written in past tense. Steps are illogical

Not written in past tense. Missing key steps.

Written in past tense. Missing key steps.

Written in past tense. Missing minor steps.

Written in past tense. Experimental details are comprehensive.

5

Results: Figures, graphs,

tables, etc

0.125No Results have been provided.

Disorganised presentation of data. Missing

essential support data. No relevant

calculation is shown.

Disorganised presentation

of data. Missing essential

support data. No relevant

calculation is shown

Data is organized & expressed in a table & graph (if

appropriate). Missing some major support

data. No relevant calculation is

shown

Data is organised well

in table and graphs.

Missing some minor support data. Relevant calculations are shown, including

units.

Exemplary presentation of supporting data.

Relevant calculations are shown including units with very

good explanation.

6 Discussion 0.125No

information is provided.

No relevant information is

provided

Information lacks clear direction.

Information does not relate to topic. No

Sources of error

Paragraphs have direction but are too broad for the

scope of the paper. Some

sources of error are discussed but no suggestions

are made to avoid, reduce or adjust for such

error.

Good qualitative

data (observations) is mentioned. Good sources of error are

discussed and some

suggestions are made to

avoid, reduce or adjust for such error.

Paragraphs are relevant and

support purpose. Very good

qualitative data (observations) is

mentioned. Exemplary

sources of error are discussed and some suggestions are made to avoid, reduce or adjust for such error..

Conclusions Conclusions


Comments:____________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

____________

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5.1 Punctuality

Punctuality is evaluated in Rubric 2. However, the student who late more than 20 minutes is

considered absent for the lesson and cannot submit lab report.

5.2 Late Submission Penalty

All the report should be submitted 2 weeks after the date of the experiment. (By 5 pm). Student

must submit a hardcopy version only.

Lab report is evaluated by using Rubric 1. However, the following penalties will be applied for

reports submitted after the deadline.

On time No penalty

1 day late 25%penalty



4+ day late 100%penalty

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Year 1 Semester 1: Lab Investigation 1

Related Subject Title Objective Equipment & Apparatus

Engineering Mechanics/Static

Experiment 1: Truss Structure

To determine forces on each joint of the truss structure.

Truss structure apparatus


Experiment 2:Deflection of Simply Supported Beam

The objective of these experiments is to establish relationship between deflection and applied load.

A steel channel base with two simple supports


Experiment 3: Efficiency of a Single Thread Worm Gear

To determine the efficiency of a single thread worm gear

Single Thread Worm Gear apparatus


Experiment 4:Friction on an Inclined Plane

To determine angle of friction and coefficient of static and dynamic friction for various materials.

An inclined plane with a pulley over the top edge

Design I/Basic Skills

Experiment 5: Welding

To join two metal together permanently Arc welding

Design I/Basic Skills

Experiment 6:Corrosion Test

To measure the corrosion rate of steel

in different environment

Engineering Material

Experiment 7: Hardness Test

To determine the hardness of four materials using Brinell testing

A Brinell desktop device- Steel and other material balls- Measurement apparatus (ruler, caliper, and divider)

Engineering Experiment 8: To investigate how the energy absorbed Charpy Impact Test apparatus

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Material Impact Test during deformation and fracture of material during impact test in various temperatures.

Engineering Material/ Solid Liquid Gases

Experiment 9: Tensile Test I

To calculate the elastic, plastic and ultimate load for the given material and draw the stress strain diagram.

Tensile and compression machine- Specimen (steel, copper, aluminium, and brass)- Measurement apparatus (ruler, caliper, and divider)

Solid Liquid Gases

Experiment 10: Marcet Boiler

To demonstrate the relationship between the pressure and temperature of saturated steam in equilibriumTo demonstrate of the vapour pressure curve

A stainless steel pressure vessel fitted with high pressure immersion electrical heater, safety relief valve, temperature and pressure measuring devices.

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FACULTY OF ENGINEERING & BUILT ENVIRONMENT

SUBJECT: EME3401 LABORATORY INVESTIGATIONS 1

EXPERIMENT 1: TRUSS STRUCTURE

1.0 OBJECTIVE

To establish relationship between each truss member and applied load

2.0 THEORY/INTRODUCTION

A truss is a structure composed of slender members joined together at their end points. Joint

connections are formed by bolting or welding the ends of the members to a common plate, called

a gusset plate, or by simply passing a large bolt or pin through each of the members. Two

important assumptions are necessary to design both the members and the connections of a truss:

i. All loadings are applied at the joint

ii. The members are joined together by smooth pins

Because of these two assumptions

• Each truss member acts as a two force member

• The forces at the ends must be directed along the axis of the member

• If the force tends to elongate the member, it is a tensile force

• If the force tends to shorten the member, it is a compressive force (refer to Figure 1)

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Figure 1 Nature of the force in a truss

3.0 APPARATUS

i. A modular truss kit.

ii. A set of weight for applying load to the truss.

iii. A 16 channels data acquisition system.

4.0 PROCEDURES

1. Switch on the data acquisition module. For stability of readings, the data acquisition

must be switched on 10 minutes before taking readings.

2. Use the truss configuration below:

Figure 2 Modular Truss Apparatus

3. Check the truss according to the selected configuration.

4. One end of the plane truss on the roller support and the other on the pin support (please

ensure that the centre of the joint is located on the knife edge and at the centre of the

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roller).

5. Ensure that the pinned support is properly secured to the frame.

6. Attached the weight hook to the joint to be loaded.

7. Empty the weight hook so that the truss is free from applied load.

8. Connect the wire from the load cell to the data acquisition module, each load cell

occupying once channel of the module.

9. ‘On’ the module(s) that is attached to the load cell by clicking the ‘On’ button on the

Module on/off dialog box.

10. For the selected module(s) ‘on’ the channels that is connected to the truss members and

the loading jack.

11. Some figures will be displayed in the boxes of the chosen channels. These figures are

the loads in the members measured in Newton’s.

12. Record the initial readings (0 Newton’s in Channel 6) and other 5 channels.

13. Start put on the weight to the hook to apply loads in the downward direction and

observe the readings for the 6 channels.

14. Repeat step 13 for more load increments.

15. At the end of the experiment, export the data to the excel spreadsheet and carry out the

necessary analysis.

5.0 RESULTS

Table 1 Measured Forces in Member of Truss

Members Initial Readings Final Reading in Members

Load / Jack 0 Newton 10 20 30 40 50 60

Member 1

Member 2

Member 3

Member 4

Member 5

Member 6

i. Draw the truss and indicate the loaded joint.

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ii. Calculate the average force in each member for each load increment. Remember to

subtract the initial reading from the data acquired for each load increment.

iii. Fill the results in Table 1.

iv. Plot the graph of forces in the members verses the applied load for the experimental and

theoretical case.

v. Determine the percentage error by calculating the slope of each graph.

Percentage Error=T h eoretical Slope−Experimental SlopeT h eoretical Slope

×100 %

6.0 DISCUSSION

i. From the plotted graph, compare the experimental and theoretical case.

ii. State the relationship between the applied load and the force in the members.

iii. State the possible source of errors. Comment on the accuracy of the experiment and ways

of improving it.

7.0 REFERENCES

i. J.L. Meriam & E. Kraige. 2006. Engineering Mechanics – Vol 1. Statics, 6th Ed. Wiley.

ii. R.C. Hibbeler. 2007. Engineering Static, 11th Ed. Prentice Hall.

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EXPERIMENT 2: DEFLECTION OF SIMPLY SUPPORTED BEAM

1.0 OBJECTIVE

To compare the theoretical and experimental values of the deflection in the simply supported

beam


The maximum deflection for a simply supported beam with a single concentrated load applied at

the mid span of the beam is:

δ= W L3

48 EI

Given,

W = applied load, N

L = Length of the beam

E = Young’s Modulus of elasticity of the beam, N/m2 (200 GPa for steel)

I = second moment of inertia, m4

3.0 APPARATUS

A steel channel base with two simple supports, a set of weight with load hanger, dial gauge and

measurement apparatus (ruler, calliper, divider, etc)

4.0 PROCEDURES

1. Measure the dimensions of the mild steel beam and note down the reading accordingly.

2. Position the “C” hook at the mid span of the beam.

3. Place the beam on top the supports.

4. Record the beam span between two supports.

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5. Set the dial gauge at the mid span of the beam.

6. Adjust the dial gauge to get zero reading.

7. Load the beam with the load hanger together with the weight provided and note down

the corresponding deflection.

8. Repeat step 6 to get the average value of the deflection under such load.

9. Repeat step 5 – 7 to get 5 readings.

5.0 RESULTS

i. Tabulate the results obtained and plot the deflection against the load.

ii. Using the deflection equation, calculate and plot theoretical values of deflection on the

same graph.

6.0 DISCUSSION

i. Compare and comment on the difference between the experimental and theoretical

values.

ii. Comment on the accuracy of the experiment and ways of improving it.

7.0 REFERENCES

i. G.E. Dieter, Mechanical Metallurgy, McGraw-Hill Inc., New York, 1986.

ii. F.A. McClintock and A.S. Argon, Mechanical Behavior of Materials, Addison-Wesley

Inc., Reading, Mass., 1966.

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EXPERIMENT 5: WELDING

1.0 OBJECTIVE

To demonstrate welding process to join two work pieces


Welding is a fabrication process that joints two or more materials together, usually metals or

thermoplastics. This is often done by melting the works pieces and adding a filler material to

form a pool of molten material that cools to become a strong joint. Many different energy

sources can be used for welding, including a gas frame, an electric arc, a lase, an electron beam,

friction, ultrasound.

Shielded metal arc welding (SMAW) is one of the most common types of arc welding as

shown in Figure B. Its electric current is used to strike an arc between the base material and

consumable electrode rod, which is made of steel and covered with flux that protects the weld

area form oxidation and contamination by producing CO2 gas during the welding processes.

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Figure 1 Shielded metal arc welding (SMAW)

3.0 APPARATUS

iv. Welding machine

v. Safety goggles

vi. 2 Machining plates

4.0 PROCEDURES

4.1 Operation Required

10. Welding

11. Finishing

12. Inspection

4.2 Lab Procedures

1. Wear gloves and screen

2. Make both of the machining plates same parallel to get proper butt position with 3 mm

space between the edges.

3. Wear long sleeve jackets and gloves. Prepare welding helmets with dark face plates and

make sure its plastic screen is clear to see through.

4. Start welding gently in the directional fashion from one end. Then, weld on another side

reversely.

5. After completing the weld, chip out the oxidized layer and clean with a wire brush.

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http://en.wikipedia.org/wiki/File:SMAW_weld_area.svg


Note: After operation, return tools and clean machine.

5 RESULTS

Figure 1 Expected Result

6 DISCUSSION

i. Place your specimen on an A4 paper and dimension it out with suitable marker pen. Take

a photo of it and insert the photo into your lab assignment. Analyze the welding result

and describe possible aspects influence its quality.

ii. Discuss on safety issue of workshop

iii. Comment on the accuracy of the experiment and ways of improving it

iv. Comment on any discrepancy and sources of error of the experiment.

7 REFERENCES

i. Larry Jeffus 1983, Welding Principles and Application, 5th Edition, Thomson Learning,

Inc, USA.

ii. B. H. Amstead, Philip F. Ostwald, Myron Louis Begeman 1987, Manufacturing

Processes, 8th Edition, John Wiley & Sons Inc, USA

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EXPERIMENT 6: CORROSION TEST

1.0 OBJECTIVE

To measure the corrosion rate of steel in different environment


Corrosion as the gradual chemical or electrochemical attack on a metal by its surroundings such

as the metal is converted into an oxide, salt or some other compound which results to loss of

strength, hardness, toughness and other desirable mechanical properties [1].

The method of weight loss test can be used in the detection of the corrosion due to corrosive

media. The weight loss was determined as difference between the initial and final weight losses

after removal of the corrosive product [2].

Corrosion Rate=87.6 wρAT

Where:

w=weight loss (g)

=density of copper (g/cm3)

A=area (cm2)

T=time (min)

3.0 APPARATUS

250 cm3 beaker flask, brush and cleaning materials, mettler electronic weigh balance machine,

HCl solution (concentration 1 M), NaCl salt + rain water to form a solution (concentration 1 M),

10 specimens of 2.5 cm length, 2.2 cm width, 0.1cm height steel sheet

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4.0 PROCEDURES

1. Measure the initial weight of 5 specimens using mettler electronic weigh balance

machine.

2. Immerse the specimens to HCl acid solution in separate flask.

3. Refine the specimens in HCl acid solution for 5 different observation times.

4. Remove the specimens from HCl acid solution.

5. Clean the surface of the specimens with a brush and distilled water carefully.

6. Dry and reweight the specimens.

7. Repeat step 1 to 6 replacing HCl acid solution with NaCl salt + rain water solution.

5.0 RESULTS

Table 1 Specimens in HCl acid (concentration 1 M)

Specimen

no

Initial weight (g) Final weight (g) Exposure time

(min)

Corrosion rate

(cm2/min)

1

2

3

4

5

Table 2 NaCl salt + rain water to form a solution (concentration 1 M)

Specimen

no

Initial weight (g) Final weight (g) Exposure time

(min)

Corrosion rate

(cm2/min)

1

2

3

4

5

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i. Prepare a graph with weight loss (g) vs. Exposed time (min) for the specimen in two

media.

ii. Prepare a graph with corrosion rate (cm2/min) vs. Exposed time (min) for the specimen in

two media.

6.0 DISCUSSION

i. From the plotted graphs, discuss the effect of corrosive media to the weight loss of

copper

ii. From the plotted graphs, discuss on the corrosion rate (cm2/min) of copper in two media.

iii. Name contributing factors to corrosion in metal and preventive methods.

iv. Comment on the accuracy of the experiment and ways of improving it

7.0 REFERENCES

i. R.U. Evan, An Introduction to Metallic Corrosion, Edward Arnold Publisher, London,

1963.

ii. S. Abdulmaruf and D.D. Dajab, Corrosion Behaviour of Copper Immersed in Different

Environment, Materials Society of Nigeria (MSN), Zaria, 3rd edition, 2007.

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EXPERIMENT 7: BRINELL HARDNESS TEST

1.0 OBJECTIVE

To determine the hardness of materials using Brinell hardness test


The Brinell hardness test was one of the most widely used hardness tests with a fixed load that its

indentation is proportional to the material’s hardness. Hardness is a measure of a material’s

resistance to localized plastic deformation. By varying the test force and ball size, nearly all

metals can be tested. Brinell harness values are considered test force independent as long as the

ball size/test force relationship is the same.

The Brinell number normally ranges from HB 50 to HB 750 for metals. The depth or size of

the resulting indention is measured, which in turn is related to a hardness number; the softer the

material, the larger and deeper is the indention, and the lower the hardness index number.

Hardness test is performed more frequently than other mechanical test because it is simple,

inexpensive and most important, it’s non-destructive test. The BHN is calculated according to

the following formula:

HB= PπD×Depth

= 2 F

πD( D−√ D2−d2 )

where, HB = Brinell hardness number

F = Imposed load (kg)

D = Diameter of the spherical indenter (mm)

d = Diameter of resulting indenter impression (mm)

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From Brinell hardness test, other mechanical properties of material will be obtained, which is

tensile strength,

Tensile strength = (3.45 x HB) MPa

or

Tensile strength = (500 x HB) psi

3.0 APPARATUS

A Brinell desktop device, steel and other material balls, measurement apparatus (ruler, caliper,

divider, etc)

4.0 PROCEDURES

1. Wind up pressure in the pressure cylinder until the screw rises about 5 cm.

2. Replace this pressure plate with Brinell test unit (10 mm steel ball).

3. Screw the lower pressure plate in position.

4. Position the steel test piece on the lower pressure plate, so that the center of the steel

ball is at least 20 mm from the edge.

5. Slowly wind up the pressure to 10kN.

6. Hold this load pressure for about 15 seconds.

7. Measure the diameter of the indentation using the magnifying lens.

8. Repeat the experiment using the other test pieces.

9. Calculate the tensile strength of the specimens.

5.0 RESULTS

Table 1 Brinell hardness test

Material Diameter of Indentation,

d (mm)

Brinell Hardness

number, HB (N/mm2)

Tensile strength of the

material (MPa)

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Prepare a graph with Brinell Hardness number, HB against tensile strength of the material.

6.0 DISCUSSION

i. A 10 mm diameter Brinell hardness indenter produced an indentation 2.50 mm diameter

in a steel alloy when a load of 1000 kg was used. Compute the HB of this material.

ii. What will be the diameter of an indentation to yield a hardness of 300 HB when 500 kg

load is used?

iii. Compare the graph plotted from experiment data to that of the calculated data with

explanation.

iv. Comment on another appropriate hardness tests for the specimens.

v. Comment on the accuracy of the experiment and ways of improving it.

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RESULT SAMPLE

Material Diameter of Indentation,

d (mm)

Brinell Hardness

number, HB (N/mm2)

Tensile strength of the

material (MPa)

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EXPERIMENT 8: IMPACT TEST

1.0 OBJECTIVE

To investigate how the energy absorbed during deformation and fracture of material during

impact test in various temperatures.


The Charpy impact test continues to be used nowadays as an economical quality control method

to assess the notch sensitivity and impact toughness of materials. It is usually used to test the

toughness of metals. Similar tests can be used for polymers, ceramics and composites.

Figure 1 Charpy V-notch specimen and impact test device

The Charpy impact test usually measures the energy absorbed by the high strain rate fracture of a

standard notched specimen. The specimen is broken by the impact of a heavy pendulum hammer,

falling through a fixed distance (constant potential energy) to strike the specimen at a fixed

velocity (constant kinetic energy). Tough materials absorb a lot of energy when fractured and

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brittle materials absorb very little energy. A scale on the Charpy impact test device will record

the amount of energy (joules) associated with this deformation and fracture of the specimen.

3.0 APPARATUS

i. A Charpy impact test device.

ii. Steel material Charpy U-notch specimen (4 specimens)

iii. Dry ice

iv. Burner

v. Measurement apparatus (ruler, caliper, divider, thermometer, etc)

4.0 PROCEDURES

1. Turn the pointer to the SET position.

2. Grab the specimen with tongs and get ready to place the specimen into the Charpy

impact test device.

3. Be sure nobody is in the area where they could be injuring by the swinging pendulum.

Lift the pendulum and latch it into the high position.

4. Place the specimen into the device with the U-notch facing away from the pendulum.

5. Step back behind the guard rail and release the pendulum by “punching” the lever with

the black knob at the top of the Charpy device.

6. Press and hold the brake button as soon as the pendulum completes one full swing.

7. Record the impact energy during deformation and fracture of your specimen.

8. Repeat the experiment with specimens that have different temperature.

5.0 RESULTS

Material : _____________

Table 1 Impact Test Result

No Temperature (OC) Impact Energy (Joules)

1

2

3

4

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Prepare a graph with temperature against impact energy.

6.0 DISCUSSION

i. Discuss the toughness of material in the different temperatures.

ii. Establish the relationship between impact energy and toughness of the specimens with

temperatures.

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EXPERIMENT 9: TENSILE TEST 1

1.0 OBJECTIVE

To determine the yield strength, ultimate strength, Young Modulus (Elastic Modulus), and

behavior of a given material when subjected to uniaxial loading and plot the graph of stress

versus strain.


Axial loading is produced by two or more collinear forces acting along the axis of a long slender

member, such as mild steel bar shown in Figure A. this type of loading occurs in many

engineering elements, including individual members that make up machine, bridge and building

trusses. When a structure member or machine component is subjected to the external forces

(applied loads and support reactions), internal resisting forces will develop within the member or

component to balance the external forces.

In the simplest qualitative terms, stress is the intensity of internal force on the cross-sectional

area of a body. In this test, the distribution of internal force has a resultant force that is normal to

exposed cross-sectional area of a simple bar. Thus,

Stress(σ )=Force( F )Area( A )

When the axial loading is applied to the body, individual points of the body generally move

with the direction of the external force. This movement of points is generally known as

displacement (vector quantity) that will involve a translation and/or rotation of the body as a

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whole and neither the size nor the shape of the body is changed. The change in any dimension

associated with these displacements is known as deformation.

A normal strain is the quantity used to measure the change in size (elongation) during

deformation. The strain may be result of a stress, of a change in temperature, or of other physical

phenomena (grain growth or shrinkage). In this test, only strain resulting from changes in stress

is considered. The change in length of a simple bar under an axial loading is:

Strain(ε )=Elongation(δ )

Original Length( L0 ¿¿

It is often necessary to relate loads and temperature changes on a structure to the

deformations produced by the loads. Experience has shown that the deformations caused by

loads are essentially independent of each other. Thus, a ratio of stress to strain that measure the

stiffness of a body is called Young’s Modulus (Elastic Modulus). It is always the constant of

proportionality between stress, and strain at stresses below the proportional limit:

Elastic Modulus( E )=Stress(σ )Strain (ε )

This relationship between loads and deformation in a structure or machine components can

be obtained by plotting a stress-strain diagram. It also depends on the dimension of the members

as well as type of material they are made.

By analyzing the stress-strain curve of a body, a number of mechanical properties of the

material can be determined. Yield strength is defined as the stress required to produce a specified

amount of plastic deformation or permanent set in the body. The yield strength is always a

practical measure of the limit of elastic action of a material:

Yield Strength=Load at the lim it proportionalityArea

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The maximum stress on the original cross-sectional area that develops in the body before

fracture is called ultimate strength or ultimate tensile and the term can be modified as

compressive or shearing strength:

Ultimate Strength=Maximum loadArea

When the ultimate strength of the body is reached, the cross-sectional area of the body will

start to decrease or neck down as Figure 2 and the resultant force that can be carried by the

specimen decreases until rupture.

Figure 1 Gauge marks for uniaxial loading

In this test, a specimen as shown in Figure 1, will be prepared and held rigidly between a

fixed beam and a moving beam (crosshead). A dial is used to measure the stress that built up in

the material as its length is increased by moving the crosshead.

Figure 2 Neck down until rupture

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3.0 APPARATUS

i. Tensile test machine

ii. Specimen (Steel, copper, aluminum, and brass)

iii. Measurement apparatus (ruler, caliper, divider, etc)

4.0 PROCEDURES

1. Measure the diameter of the specimen at various places and get the average.

2. Mark the specimen at 10 mm interval along its length.

3. Punch 2 marks on the specimen using the provided puncher.

4. Fix the specimen to the machine by pushing the top grip upwards and inserting the

specimen into bottom grip. Lower the top grip so that the specimen top of the specimen

is in the grip.

5. Fix the extensometer to the specimen. Make sure that the screw pins are resting in the 2

marks.

6. Record the dial gauge readings into Table A.

7. Power on the machine using power switch.

8. Press the motor switch to position A.

9. When the reading is about 0.5 – 1 kN, stop the machine. This is the preload to take up

all the loose fittings in the machine.

10. Create zero readings of the dial gauge and the load indicator.

11. Turn the motor switch to position A.

12. Record the readings of the load cell, the extensometer and the dial gauge.

13. When the extensometer reading starts to increase at a fast rate, remove the extensometer

and continue the experiment using the dial gauge only. Continue recording until the

specimen breaks.

14. Switch off the motor by pressing the motor switch position to “O”.

15. Remove the specimen from the grips and join back the specimen.

16. Measure the final length (distance between 5 markings with the break at the center

mark) and diameter at the broken section.

17. Press the motor switch to position M to return the crosshead to the original position.

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5.0 RESULTS

Specimen diameter = mm

Cross-sectional area = mm2

Gauge length = mm

Table 1 Tensile Test

Load, F (N) Dial Gauge

Reading (mm)

Calculated Stress, σ

= F/A (N/mm2)

Calculated

Length ΔL (mm)

Calculated

Strain,

ε = ΔL/L0

(mm./mm)

i. Prepare a graph with Stress vs. Strain curve for the specimen and point out its elastic

modulus, yield Strength and ultimate tensile strength.

ii. Determine the following for the specimen: reduction in area, percentage of elongation,

yield strength and ultimate strength.

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6.0 DISCUSSION

i. From the plotted graph, establish the relationship between stress and strain with

explanation

ii. Comment on the accuracy of the experiment and ways of improving it.

7.0 REFERENCES

iii. G.E. Dieter, Mechanical Metallurgy, McGraw-Hill Inc., New York, 1986.

iv. F.A. McClintock and A.S. Argon, Mechanical Behavior of Materials, Addison-Wesley

Inc., Reading, Mass., 1966.

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EXPERIMENT 10: MARCET BOILER

1.0 OBJECTIVE

i. To demonstrate the relationship between the pressure and temperature of saturated steam

in equilibrium with water

ii. To determine the vapour pressure curve.


An ideal gas obeys the equation of state that relates the pressure, specific volume or density, and

absolute temperature with mass of molecule and the gas constant, R.

PV =mRTM

Where,

P= Absolute pressure

V= Volume

n= Amount of substance (moles)

R= Ideal gas constant

T= Absolute temperature (K)

However, real gas does not absolutely obey the equation of state. A few changes on the ideal

gas equation of state allow its application in the properties of real gas.

When energy increases within water, the increasing of activities among the molecules

enables the increase in the number of molecule escape from the surface until an equilibrium state

is reached. The state of equilibrium depends on the pressure between the water surface and

steam. At lower pressure, the molecules become easier leaving the water surface while less

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energy required in achieving the state of equilibrium (boiling point). The temperature where

equilibrium occurs at a given pressure level is called saturated temperature.

The Marcet Boiler is used to investigate the relationship between the pressure and

temperature of saturated steam in equilibrium with water at all temperature levels between the

atmospheric pressure and 10 bars. The experimental slope (dT/dP)SAT obtained is compared to the

theoretical value determined through calculation from the steam table. Clausius-Clapeyron

states:

( dTdP )

SAT=

Tv fg

h fg

( dTdP )

SAT=

T (v f−v g )hf−hg

Where,

h f +h fg=hg

h fg=hg−h f

( dTdP )

SAT=

T (v f−v g )hfg

=Tvg

h fg as vg >> vf

In which,

vf = specific volume of saturated liquid

vg = specific volume of saturated vapor

hf = enthalpy of saturated liquid

hg = enthalpy of saturated vapor

hfg = latent heat of vaporization

3.0 APPARATUS

i. HE169 Marcet boiler which shown in Figure 1

a. Pressure transducer

b. Temperature controller/Indicator

c. Pressure indicator

d. Control panel

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e. Bench

f. Bourdon tube pressure gauge

g. Temperature sensor

h. Pressure relief valve

i. Water inlet port & valve

j. Heater

Figure 1: HE169 Marcet boiler

4.0 PROCEDURES

1. Turn on the power supply switch.

2. If the boiler is initially filled with water, open the valves at the level side tube to check

the water level. Pour in additional distilled water if necessary. Then, close the valves.

3. Set the temperature controller to 185°C, which is slightly above the expected boiling

point of the water at 10 bar (abs).

4. Open the valve at feed port and turn on the heater.

Important: Always make sure that the valves at the level sight tube are closed before

turning on the heater as the sight tube is not designed to withstand high pressure and

temperature.

Prepared by TF Go


5. Observe the steam temperature rising as the water boils.

6. Allow steam to come out from the valve for about 30 seconds, and then close the valve.

This step is important to remove air from the boiler as the accuracy of the experimental

results will be significantly affected when air is present.

7. Record the steam temperature and pressure when the boiler is heated until the steam

pressure reaches 10 bar (abs).

Warning: Never open the valves when the boiler is heated as pressurized steam can

cause severe injury.

8. Then, turn off the heater and the steam temperature and pressure will begin to drop.

Allow boiler cool down to room temperature.

9. Record the steam temperatures at different pressure readings when the boiler is heated

and cooled.

10. Switch off the heater and allow the boiler temperature to drop.

Note: Do not open the valve at the water inlet port as it is highly pressurized at high

temperature.

5.0 RESULTS

Atmospheric pressure : _____________ bar

Atmospheric temperature : _____________ (0C)

Table 1 Data Collected and Calculated Results

Pressure, P

(bar)

Temperature, T

Measur

ed

Slope,

dT/dP

Calculate

d

Slope,

Tvg/hfg

absolu

te

Gauge Increase

(0C)

Decreas

e

(0C)

Average

Tavc (0C)

Average

Tavc (K)

1.0

1.5

2.0

2.5

3.0

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3.5

4.0

4.5

5.0

5.5

6.0

6.5

7.0

7.5

8.0

i. Prepare a graph with temperature, T against absolute pressure, P.

ii. Measure/calculate the slope of the graph using certain points.

iii. Plot ( dT

dP )SAT versus P and

Tv fg

h fg versus P on a same graph.

6.0 DISCUSSION

i. Give the reason why it is necessary to remove air from the boiler at the beginning of the

experiment.

ii. Compare the graph plotted from experiment data to that of the calculated data with

explanation.

iii. Comment on any discrepancy and sources of error of the experiment.

iv. Discuss the liquid and vapor behavior observed through the experiment and list some

examples of its industrial applications.

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RESULT SAMPLE (2013 JAN SEMESTER)

Table 1.

Pressure, P Temperature, T Measured

Slope

( dTdP )

SAT

Calculated

Slope, T v g

hfg

Percentage

error, %Gauge Absolute (°С) (K)

0 1 99.5 372.5 0.2795

0.4 1.5 111.2 384.2 0.234 0.2001 14.49

0.9 2.0 120.2 393.2 0.180 0.1582 12.11

1.5 2.5 127.4 400.4 0.144 0.1319 8.40

2.0 3.0 133.6 406.6 0.124 0.1139 8.15

2.5 3.5 139.0 412.0 0.108 0.1006 6.85

3.0 4.0 143.9 416.9 0.098 0.09036 7.80

3.5 4.5 148.3 421.3 0.088 0.08225 6.25

4.0 5.0 152.2 425.2 0.078 0.07566 9.93

4.5 5.5 155.9 428.9 0.074 0.07009 5.28

5.0 6.0 159.2 432.2 0.066 0.06540 0.91

5.5 6.5 162.3 435.3 0.062 0.06137 1.02

6.0 7.0 165.2 438.2 0.058 0.05786 0.24

6.5 7.5 168.0 441.0 0.056 0.05480 2.14

7.0 8.0 170.6 443.6 0.052 0.05207 0.13

Sample Calculations:

To convert bar (abs) to abs.

1bar X 100 kPa

1 ¿̄ ¿ = 100 kPa

To convert Temperature, T to Temperature, K

T (K) = T (°С) + 273

= 99.5 + 273

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= 372.5 K

To calculate measured slope,

( dTdP )

SAT=

(384.2−372.5 ) K(150−100 ) kPa

= 0.234

To calculate calculated slope,

T v g

hfg=

(372.5 K )(1.6941 m3

kg)

2257.5 kJ /kg

= 0.2795

To calculate the percentage error, %

Measured Slope−Calculated SlopeMeasured Slope

X 100%= 0.234−0.2001

0.234X 100%

= 14.49%

0.0 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0320.0

340.0

360.0

380.0

400.0

420.0

440.0

460.0

Absolute Temperature, T against Absolute Pressure, P

Absolute Pressure, P

Abso

lute

Tem

pera

ture

, T

Figure 1: Absolute Temperature versus Absolute Pressure

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0.0 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.00.00

0.05

0.10

0.15

0.20

0.25

0.30

Change of Temperature, against Absolute Pressure, P

Measured Slope against Absolute PressureCalculated Slope against Absolute Pressure

Absolute Pressure

Slop

e

Figure 2: The Change of Temperature against Absolute Pressure

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Mechanical Engineering

Laboratory Investigation I

Hand Book

Prepared by TF Go

SEGi University

[SEGi University]


Subject Info

Subject : Laboratory Investigations 1

Course : BME

Subject Code : EME3401

Subject Status : Major

Semester : 1

Assessment : Lab report – 70%;

Presentation – 20%

Practical – 10%

Lecturer Details

Lecturer : Mr/Ms…..

HP/Tel : 3047, SEGi UC extension

E-mail Address : [email protected]

Learning Objectives

To introduce students to experimental methods and technical lab report writing

To reinforce basic mechanical engineering concepts and safety procedures through

exposure to laboratory experimental.

To develop students’ fundamental practical skills in operating engineering laboratory and

workshop equipment.

Learning Outcomes

Explain the basic concepts involved in engineering statics and materials via experimental.

Explain the basic concepts involved in solids, liquids and gases via experimental.

Work effectively in a team and develop soft skills such as communication

Generate good report writing skill

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Introduction

This laboratory manual available to all students at the beginning of the semester contains the

detailed information about the experiment objectives with each having a brief introduction, a

short description of the facility, suggestions for summary and a few references. Students must

prepare themselves for the next scheduled experiment following the appropriate hand-out.

If you are unable to attend a practical class for a valid reason, please inform the lecturer

before the class. Unexplained absences from laboratory classes may results in a mark of zero for

that experiment. You cannot submit a report if you have not attended the practical class.

Your report should be submitted 2 weeks after the date of the experiment. (By 5 pm).

You must submit a hardcopy version only. Late submission will be subjected to a penalty.

Important Notes:

Plagiarism – Plagiarism is a form of cheating. Do not use someone else’s ideas or words and

submit them as your own. You will get a 0% grade for plagiarising (even copying your

friend’s work)

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Lecture Schedule and Suggested Private Study Schedules

Week Day/Date Lecture Topic/Name of Experiment Venue1 11/01/13 Introduction + Overview2 14/01/13 Lab 1 – Gear Train EM3 21/01/13 Lab 2 – Shear Force EM4 28/01/13 Public Holiday5 04/02/13 Lab 3 – Bernoulli’s Principle FM

12/02/13 CNY Break6 18/02/13 Lab 4 – Friction Loss FM7 25/02/13 Lab 5 – Impact Jet FM8 04/03/13 Lab 6 – Free Vibration 1 EM9 11/03/13 Lab 7 – Free Vibration 2 EM/MT10 18/03/13 Lab 8 – Turning WS11 25/03/13 Lab 9 – Tensile Test WS12 01/04/13 Lab 10 – Bending WS13 08/04/13 Revision14 15/04/13 Presentation

Note:EM = Engineering Mechanics LabMT = Material Testing LabFM = Fluid Mechanics LabWS = Workshop

Ms Go Tze FongJanuary 2013

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Laboratory Hand Book Lab1 25Aug

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Transcript of Laboratory Hand Book Lab1 25Aug