Torsion test

Submitted by: Mokkapati Shanmukha Sree

Roll number: 210626

AE351 - Experiments in Aerospace Engineering - II

Department of Aerospace Engineering
Aerospace Structures Laboratory
Date of the experiment: 22.03.2024
1 Objective
Perform a torsion (shear) test on a shaft with a circular cross section and measure the shear modulus of a material using
two different methods.

2 Introduction
Torsion, a phenomenon where an object undergoes twisting when subjected to torque, holds significant importance across
various engineering domains. In mechanical systems like shafts, springs, and gears, torsional forces are commonplace,
making it imperative to comprehend and analyze this mode of deformation. By understanding torsion, engineers can
design structures and components capable of withstanding twisting forces without compromising their integrity or func-
tionality. This understanding forms the basis for ensuring the safety, reliability, and optimal performance of mechanical
systems in diverse applications.
A critical aspect of studying torsion is grasping the significance of the shear modulus (G), a fundamental material prop-
erty. Shear modulus quantifies a material’s resistance to shear deformation, providing crucial insights into its mechanical
behavior under torsional and shear loading conditions. This property plays a pivotal role in material characterization,
aiding engineers in assessing stiffness, predicting performance under varying loads, and making informed decisions dur-
ing design and analysis processes. Moreover, the shear modulus serves as a quality control parameter in manufacturing,
ensuring that materials meet specified mechanical property requirements for intended applications.
Various methods exist to calculate the shear modulus of a material, each offering insights into its mechanical behavior
under different conditions. Torsion testing stands out as a direct and reliable method for determining the shear modulus.
By conducting torsion tests on specimens of known geometry and dimensions, engineers can measure applied torque and
resulting angle of twist. Analysis of experimental data allows for the derivation of the shear modulus using equations
derived from the torsion equation. Additionally, shear stress-shear strain measurements provide another avenue for calcu-
lating the shear modulus by subjecting material samples to controlled shear loading and measuring resulting stresses and
strains. Dynamic Mechanical Analysis (DMA) is yet another method, involving subjecting materials to oscillatory shear
deformation and analyzing their mechanical response, including storage and loss moduli.
In this lab report, we focus on utilizing the torsion testing method to determine the shear modulus of a material. This
approach offers a comprehensive understanding of the material’s torsional behavior, facilitating informed decisions in
material selection, design optimization, and quality control processes across various engineering applications.

2.1 Explanation of Theoretical Principles Behind the Torsion Test

1. Shear Stress (τxy ) and Shear Strain (γxy ):
When a cylindrical specimen is subjected to torsional loading, shear stress (τxy ) is developed in the material due to
the applied torque. Shear stress is defined as the force per unit area acting parallel to the cross-sectional area of the
specimen. This stress induces shear strain (γxy ) within the material, which represents the deformation or angular
displacement of the material relative to its original position.
2. Relationship Between Shear Stress and Shear Strain:
The relationship between shear stress (τxy ) and shear strain (γxy ) in a material is linear, as described by Hooke’s
law for shear deformation:
τxy = Gγxy
Here, G represents the shear modulus of the material, which quantifies its resistance to shear deformation. The
shear modulus is a fundamental material property that characterizes the material’s stiffness in shear.

3. Torsion Equation:
The torsion equation relates the applied torque (T ) to the resulting angle of twist (θ) in a cylindrical specimen. This
equation is derived from the fundamental principles of mechanics of materials and considers the geometry of the
specimen, as well as the material properties. The torsion equation is given by:

JGθ
T =
L
Where:

• T is the applied torque,

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 • J is the polar moment of inertia of the cross-sectional area of the specimen,
• G is the shear modulus of the material, and
• L is the length of the specimen.
Therefore, we have
T τ Gθ
= =
J R L
4. Derivation of Shear Modulus (G):
By rearranging the torsion equation, the shear modulus (G) can be expressed as:
TL
G=
Jθ
This equation demonstrates that the shear modulus can be determined experimentally by measuring the applied
torque (T ), the length of the specimen (L), the polar moment of inertia (J), and the resulting angle of twist (θ).
5. Shear Strain from 0-45-90 Strain Rosette Data:
From the strain transformation equation, the normal strain for a given orientation can be calculated by using the
mechanics of solids equation:

ε(θ) = ε0 cos2 (θ) + ε45 sin2 (θ) + γxy sin(θ) cos(θ)

Applying this relation at each of the gauge angles leads to:

ε0 = εx
1
ε45 = (εx + εy + γxy )
2
ε90 = εy
The shear strain can be obtained by rearranging the above expressions, where ε0 , ε45 , and ε90 are the strain values
recorded using the 0-45-90 strain gauge rosette.
This results in
γxy = 2ε45 − ε0 − ε90

6. Experimental Determination of Shear Modulus (G):

In practice, the shear modulus (G) is typically determined by conducting torsion tests on specimens of known
geometry and dimensions. The torque-angle of twist data obtained from the experiment is used to plot a graph of
torque (T ) versus angle of twist (θ). By performing linear regression on this plot, the slope of the line provides the
shear modulus (G) according to the equation:
TL
G=
Jθ
Similarly, a plot of shear stress (τxy ) versus shear strain (γxy ) can be generated from experimental data obtained
using strain measurement techniques. The slope of the resulting line from linear regression also yields the shear
modulus (G) according to the equation:
τxy
G=
γxy
These experimental methods allow engineers to accurately determine the shear modulus of materials and character-
ize their mechanical behavior under torsional loading conditions.

3 Equipments
1. A single cylindrical rod, measuring 700 mm in length and 10.22 mm in radius, crafted from aluminum alloy 6063,
is essential for the experiment. This rod will be subjected to torsional loading, where one extremity will be firmly
anchored while torque is applied to the opposite end. To gauge strain, a strain rosette will be affixed to the rod, as
illustrated in the diagram provided.

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2. Illustrated in the accompanying figure 1a, the strain rosette employed in the experiment follows the (0-45-90)
configuration, featuring three strain gauges positioned at 0, 45, and 90 degrees. Utilizing a quarter bridge circuit,
the strain rosette can transmit readings to the strain indicator for analysis.
3. The strain indicator machine is equipped with the capability to exhibit nine to twelve separate stresses concur-
rently across multiple channels. For our experiment, we harness three of these channels to acquire normal strains at
0, 45, and 90 degrees. These strain measurements are subsequently utilized in the calculation of shear strain using
Mohr’s Circle Equations.

4. These components are combined to apply torque to our specimen effectively. When a load is applied, the steel
rod acts as a shaft, rotating and imparting torque to the aluminum rod connected at its center. Weights are placed in
pans to act as the load. Circular shafts are used to attach specimens to steel rods and at other locations to configure
the setup as depicted in the provided image. To measure the displacement of the steel rod caused by torque, a dial
gauge is employed. This measurement from the dial gauge allows for the determination of the angle of twist in the
aluminum rod. A pan is loaded with 0.5 kg weight plates to apply torque to the steel shaft.

(a) Strain Rosette (b) Strain Indicator machine

Figure 1: Equipments

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3.1 Experimental Setup

Figure 2: Experimental Setup

4 Procedure
1. Set up the experiment according to the provided diagrams. Ensure proper placement of the strain rosette on the
aluminum rod. Calibrate the dial gauge and strain indicator readings to zero.

2. Place equal weights on both pans and stabilize them carefully. Ensure that the pans are balanced and not unstable.
3. Apply equal loads on both sides of the torque arm. Ensure that the weights are steady and not swinging when the
load is applied.
4. Record the following data:

• Vertical deflection of the torque arm

• Readings from the three strain gauges
5. Determine the torque, shear strain, and angle of twist for each applied load. Repeat this process five times to obtain
five datasets of dial gauge and strain readings.

6. Utilize the formulas provided in the theoretical background to calculate shear stress, shear strain, torque, and angle
of twist from the recorded loads and other readings.
7. Plot shear stress versus shear strain and torque versus angle of twist. Apply linear regression to both plots to obtain
the slopes of the curves.

8. Calculate the Shear Modulus using the slope of the straight line for both plots. The slope of the shear strain versus
shear strain plot directly gives G, while the slope of the other plot may need to be scaled to obtain G.
9. Compare the two values of G obtained from these graphs. Perform Error Analysis to identify and analyze sources
of errors in the experiment.

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5 Notations
• h: Vertical deflection of the torque arm at the gauge location (mm)
• r: Radius of the twisted rod (mm)
• s: Length of the arm up to the deflection gauge (mm)

• L: Length of the rod between two fixed ends (mm)

• T : Torque (N)
• θ: Angle of Twist (radians)
• γxy : Shear strain (µ) = 2ε45 − ε0 − ε90
TR
• τxy : Shear stress (MPa) =
J
• Least Count of the pressure-displacement scale: 0.01 mm
• Number of divisions in one complete rotation: 100 divisions
πr 4
• Polar moment of Inertia: J = 2 mm4

Given values:
• Length of the aluminum rod L: 687 mm

• Diameter of the Aluminum rod: 20 mm

• Distance from the center to the dial gauge: 140 mm
• Length of the torque arm (d): 340 mm

• Polar moment of Inertia: J = 1.5708 × 104 mm4

6 Results and Discussion

Load (N) ϵ0 (µ) ϵ45 (µ) ϵ90 (µ) h (mm) θ = tan−1 (h/s) (rad) T = Load*d (arm) (N-m) γxy (µ) τxy (MPa)
0 0 0 0 0 0 0 0 0
5 0 21 0.66 0.47 0.0033571 1.75 41.33 108.23
10 1 42.54 0.93 0.94 0.0067142 3.50 83.15 216.45
15 1 62.97 0.77 1.43 0.010214 5.25 124.17 324.68
20 0 83.73 1.30 1.94 0.0138563 7.00 166.16 432.90
25 0 104.31 1.34 2.46 0.017570 8.75 207.28 539.07

Table 1: Experimental Data

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 Figure 3: Stress vs Strain

Figure 4: Torque vs Angle of twist

JG
We can see that from figure 3, we see the slope G = 26.02GP a. And from figure, 4 we see the slope L = 482.8, i.e.,
G = 21.12GP a
% Error in G arrived from Shear stress vs Strain = 26.02−25.8
25.8 × 100 = 0.8527%
% Error in G arrived from Torque vs Angle of twist = 21.12−25.8
25.8 × 100 = 18.1395%

7 Conclusion
In the experiment, two methods were employed to determine the shear modulus of Aluminum 6063 alloy. Method 1 in-
volved analyzing the relationship between shear stress and strain directly obtained from strain rosette readings on the alu-
minum rod. This method yielded a shear modulus value 26.02 GPa, which is close to the published value of 25.8 GPa(2) .
However, there might be small errors associated with determining shear stress from torque measurements.

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 Method 2 utilized the relationship between torque and angle of twist. However, the assumption of the steel rod as a
rigid object might not hold true, leading to deformations and inaccuracies in the measured angle of twist. As a result, the
shear modulus obtained from this method was slightly lower, approximately 21.12 GPa.
Considering the sources of error in both methods, the results suggest that Method 1 is likely to be more accurate due
to the direct measurement of strain on the aluminum rod. Nonetheless, it’s essential to acknowledge the limitations and
potential errors associated with each method to ensure the reliability of the experimental findings. Overall, the obtained
shear modulus values provide valuable insights into the mechanical properties of Aluminum 6063 alloy, indicating its
stiffness under torsional loading conditions.

8 Sources of Error in the Experiment

1. If the strain rosette is not applied properly, then the equation for shear strain we have used won’t be valid, so it
should be applied properly, to get accurate results.
2. When the load was applied on the pans, they started oscillating, as they were connected with springs, so we have to
make sure that they have stopped before taking the reading, otherwise torque which we are using for calculations
will not be valid and accuracy will decrease.
3. When torque is applied to the steel rod, it will not only displace the rod, but as it is a bending moment, the dial
gauge reading will include displacement and deformation, but angle of twist should have been found only due to
the displacement of steel rod. So, this is also a source of error, although it will not cause much error.

4. There are differences in the measurements due to the errors introduced by voltage fluctuations in the electronic
equipment due to sensitivity and deformation of the shaft due to prolonged use.

References
[1] S2 - Torsion test
[2] Properties of Aluminum 6063