Measurement is the estimation of the magnitude of some attribute of an object, such as its length or weight, relative to a unit of measurement. Measurement usually involves using a measuring instrument, such as a ruler or scale, which is calibrated to compare the object to some standard, such as a meter or a kilogram. In science, however, where accurate measurement is crucial, a measurement is understood to have three parts: first, the measurement itself, second, the margin of error, and third, the confidence level -- that is, the probability that the actual property of the physical object is within the margin of error. For example, we might measure the length of an object as 2.34 meters plus or minus 0.01 meter, with a 95% level of confidence.

1. EXPERIMENTAL STRESS
ANALYSIS
UNIT – 1
MEASUREMENTS

2.  Measurement is the estimation of the magnitude of
some attribute of an object, such as its length or weight,
relative to a unit of measurement.
 Measurement usually involves using a measuring
instrument, such as a ruler or scale, which is calibrated to
compare the object to some standard, such as a meter or a
kilogram. In science, however, where accurate
measurement is crucial, a measurement is understood to
have three parts: first, the measurement itself, second, the
margin of error, and third, the confidence level -- that is,
the probability that the actual property of the physical
object is within the margin of error.
 For example, we might measure the length of an object as
2.34 meters plus or minus 0.01 meter, with a 95% level of
confidence.

3. Accuracy and Precision
 Accuracy and precision can not be
considered independently
 A number can be accurate and not precise
 A number can be precise and not accurate
 The use of the number determines the
relative need for accuracy and precision

4. ACCURACY
 Accuracy can be defined as how close a
number is to what it should be.
 Accuracy is determined by comparing a
number to a known or accepted value.

5. PRECISION
 The number of decimal places assigned to
the measured number
 It is sometimes defined as reproducibility

6. Accuracy vs. Precision for
Example 1
 Each of these statements is more accurate
and more precise than the one before it.
 Statement two is more accurate and more
precise that statement one.
 Statement three is more accurate and more
precise than statement two.

7. Example 2:
 How long is a piece of string?
 Johnny measures the string at 2.63 cm.
 Using the same ruler, Fred measures the
string at 1.98 cm.
 Who is most precise?
 Who is most accurate?

8. ACCURACY/PRECISION
 You can tell the precision of a number
simply by looking at it. The number of
decimal places gives the precision.
 Accuracy on the other hand, depends on
comparing a number to a known value.
Therefore, you cannot simply look at a
number and tell if it is accurate

9. SENSITIVITY
 Sensitivity is the study of how the
variation in the output of a model
(numerical or otherwise) can be
apportioned, qualitatively or quantitatively,
to different sources of variation.

10. RANGE
Range is used to indicate the difference
between the largest and smallest measured
values or set of data.

11. UNIT – 2
EXTENSOMETERS

12. INTRODUCTION
Extensometer is a device that is used to
measure small/big changes in the length of an
object. It is useful for stress-strain measurements.
Its name comes from "extension-meter". It was
invented by Dr. Charles Huston who described it
in an article in the Journal of the Franklin Institute
in 1879. Huston later gave the rights to Fairbanks
& Ewing, a major manufacturer of testing
machines and scales

13. TYPES OF EXTENSOMETERS
 Mechanical
 Optical
 Acoustical
 Electrical

14. MECHANICAL EXTENSOMETER

15. OPTICAL EXTENSOMETER

16. Acoustical Extensometer

17. Electrical Extensometer

18. Electrical Extensometer
A thin plastic base supports thin ribbons of metal,
joined in a zig-zag to form one long electrically
conductive strip. The entire device is typically 10
mm long, with 16 or more parallel metal bands.
When the plastic is stretched the wires become
longer, and thinner. The electrical resistance
therefore increases.

19. Unit - III
ELECTRICAL RESISTANCE STRAIN
GAUGES

20. Electrical Resistance Strain Gage
Circuits
 Electrical Properties of the Resistance Gage
R=ρL/A
Where L= Length
ρ= Resistively
A= Cross sectional area

21. Resistance Measuring Circuits
 Constant Current Circuit
 Ballast Circuit

22. Wheatstone Bridge
 The Wheatstone Bridge is the most basic of
a number of useful electrical bridge circuits
that may be used to measure resistance,
capacitance or inductance. It also finds
applications in a number of circuits
designed to indicate resistance changes in
transducers such as resistance thermometers
and moisture gages

23. Wheatstone Bridge circuit diagram

24. Wheatstone Bridge Circuit
Considerations
 Temperature Effects in the Cage
Fluctuations in ambient and in operating
temperatures produce the most severe effects
generally dealt with in strain measuring circuitry
 The problems arise primarily from two
mechanisms:
(1) changes in the gage resistivity with
temperature
(2) temperature induced strain in the gage
element

25. Temperature Compensation in the
Bridge Circuit
 Temperature compensation of the strain gage
alone does not generally eliminate thermal
problems entirely.
Such compensation is rarely exact and the
differences must usually be eliminated by careful
configuration of the Wheatstone Bridge circuit.
The ability to make such compensation is, in
fact, one of the more desirable features of this
circuit

26. Half Bridge Configuration:

27. Quarter Bridge Configuration:

28. Lead wire Temperature/Resistance
Compensation
RS = total resistance of lead wires to gage

29. BRIDGE BALANCING

30. CALIBRATION
The output from a strain gage bridge is
proportional to changes in resistance of all of the
arms. In most situations, only one or two arms are
active and it is desirable to be able to provide
some means of assurance that the circuit is
working properly.
The Wheatstone Bridge circuit is ideally
suited for this purpose because it is relatively easy
to affect a change in resistance in one or more
arms that is proportional to a known physical
parameter.

31. Calibration Circuits

32. Unit IV
Photoelasticity

33. Outline
• Theroy of Photoelasticty
• Example 1: Stress Opticon
• Example 2: GFP 1000

34. Stress Opticon
Natural
Light
Linear
Polarizer
Circular
Polarizer
(¼ wave-
length)
Sample Circular
Polarizer
Linear
Polarizer
Analyzer
Observer

35. Natural Light
Ether Particles Vibration
Light Vector (Amplitude, Direction,
Phase Angle)
Components

36. Plane Polarizer
•Nicol’s Prism:
Double Refraction
o
e
t
t
i
i n
n 
 sin
sin 
e
o n
n 
Calcium
Canada
Balsam
•Polaroid:
Energy Loss: damper

37. Circular Polarizer

38. Circular Polarizer
nl
V



2

e
o n
n 
Phase Angle:
2


 
 e
o
When
2



 

 e
o
? If
Another 1/4

39. Colors
When stressed
nl
V



2

V
 Wave Length (different for colors)
If no stress
•Different color light has different
phase angle, Rainbow appears.

40. Review—Stress Opticon
Colors

41. GFP 1000--Grey field
polariscope
Aluminum
Ring
Wrench
GFP 1000 is a strain measurement system based on photoelasticity

42. GFP 1000
Theory:

43. GFP 1000


Tension
Compression
•Orientation of ellipse measures direction of 1
• Ellipticity measures magnitude

44. GFP 1000
1
2
3
4

45. Coating

46. Unit - V
NON – DESTRUCTIVE TESTING

47. Introduction to Nondestructive
Testing

48. Outline
 Introduction to NDT
 Overview of Six Most
Common NDT Methods
 Selected Applications

49. The use of noninvasive
techniques to determine
the integrity of a material,
component or structure
or
quantitatively measure
some characteristic of
an object.
i.e. Inspect or measure without doing harm.
Definition of NDT

50. Methods of NDT
Visua
l

51. What are Some Uses
of NDE Methods?
 Flaw Detection and Evaluation
 Leak Detection
 Location Determination
 Dimensional Measurements
 Structure and Microstructure
Characterization
 Estimation of Mechanical and Physical
Properties
 Stress (Strain) and Dynamic Response
Fluorescent penetrant indication

52. When are NDE Methods
Used?
To assist in product
development
To screen or sort incoming
materials
To monitor, improve or
control manufacturing
processes
There are NDE application at almost any stage
in the production or life cycle of a component.

53. Six Most Common NDT
Methods
• Visual
• Liquid Penetrant
• Magnetic
• Ultrasonic
• Eddy Current
• X-ray

54. Most basic and common
inspection method.
Tools include
fiberscopes,
borescopes, magnifying
glasses and mirrors.
Robotic crawlers permit
observation in hazardous or
tight areas, such as air
ducts, reactors, pipelines.
Portable video inspection
unit with zoom allows
inspection of large tanks
and vessels, railroad tank
cars, sewer lines.
Visual Inspection

55. • A liquid with high surface wetting characteristics
is applied to the surface of the part and allowed
time to seep into surface breaking defects.
• The excess liquid is removed from the surface
of the part.
• A developer (powder) is applied to pull the
trapped penetrant out the defect and spread it
on the surface where it can be seen.
• Visual inspection is the final step in the
process. The penetrant used is often loaded
with a fluorescent dye and the inspection is
done under UV light to increase test
sensitivity.
Liquid Penetrant Inspection

56. Magnetic Particle Inspection
The part is magnetized. Finely milled iron particles
coated with a dye pigment are then applied to the
specimen. These particles are attracted to magnetic
flux leakage fields and will cluster to form an
indication directly over the discontinuity. This
indication can be visually detected under proper
lighting conditions.

57. Magnetic Particle Crack
Indications

58. Radiography
The radiation used in radiography
testing is a higher energy (shorter
wavelength) version of the
electromagnetic waves that we
see as visible light. The radiation can
come from an X-ray generator or a
radioactive source.
High Electrical Potential
Electrons
-
+
X-ray Generator
or Radioactive
Source Creates
Radiation
Exposure Recording Device
Radiation
Penetrate
the Sample

59. Film Radiography
Top view of developed film
X-ray film
The part is placed between the
radiation source and a piece of film.
The part will stop some of the
radiation. Thicker and more dense
area will stop more of the radiation.
= more exposure
= less exposure
The film darkness
(density) will vary with
the amount of radiation
reaching the film
through the test object.

60. Radiographic Images

61. Conductive
material
Coil
Coil's
magnetic field
Eddy
currents
Eddy current's
magnetic field
Eddy Current Testing

62. Eddy Current Testing
Eddy current testing is particularly well suited for detecting surface
cracks but can also be used to make electrical conductivity and
coating thickness measurements. Here a small surface probe is
scanned over the part surface in an attempt to detect a crack.

63. High frequency sound waves are introduced into a
material and they are reflected back from surfaces or
flaws.
Reflected sound energy is displayed versus time, and
inspector can visualize a cross section of the specimen
showing the depth of features that reflect sound.
f
plate
crack
0 2 4 6 8 10
initial
pulse
crack
echo
back surface
echo
Oscilloscope, or flaw
detector screen
Ultrasonic Inspection (Pulse-
Echo)

64. Ultrasonic Imaging
Gray scale image produced using
the sound reflected from the front
surface of the coin
Gray scale image produced using the
sound reflected from the back surface
of the coin (inspected from “heads” side)
High resolution images can be produced by plotting
signal strength or time-of-flight using a computer-
controlled scanning system.

65. Common Application of NDT
 Inspection of Raw Products
 Inspection Following
Secondary Processing
 In-Services Damage Inspection

66. Inspection of Raw Products
Forgings,
Castings,
Extrusions,
etc.

67. Machining
Welding
Grinding
Heat treating
Plating
etc.
Inspection Following
Secondary Processing

68. Cracking
Corrosion
Erosion/Wea
r
Heat
Damage
etc.
Inspection For
In-Service Damage

69. Power Plant Inspection
Probe
Signals produced
by various
amounts of
corrosion
thinning.
Periodically, power plants are
shutdown for inspection.
Inspectors feed eddy current
probes into heat exchanger
tubes to check for corrosion
damage.
Pipe with damage

70. Wire Rope Inspection
Electromagnetic devices
and visual inspections are
used to find broken wires
and other damage to the
wire rope that is used in
chairlifts, cranes and other
lifting devices.

71. Storage Tank Inspection
Robotic crawlers
use ultrasound to
inspect the walls of
large above ground
tanks for signs of
thinning due to
corrosion.
Cameras on
long
articulating
arms are used
to inspect
underground
storage tanks
for damage.

72. Aircraft Inspection
• Nondestructive testing is used
extensively during the
manufacturing of aircraft.
• NDT is also used to find cracks
and corrosion damage during
operation of the aircraft.
• A fatigue crack that started at
the site of a lightning strike is
shown below.

73. Jet Engine Inspection
• Aircraft engines are overhauled
after being in service for a period
of time.
• They are completely disassembled,
cleaned, inspected and then
reassembled.
• Fluorescent penetrant inspection
is used to check many of the parts
for cracking.

74. Sioux City, Iowa, July 19, 1989
A defect that went
undetected in an
engine disk was
responsible for
the crash of
United Flight 232.
Crash of United Flight 232

75. Pressure Vessel Inspection
The failure of a pressure vessel
can result in the rapid release of
a large amount of energy. To
protect against this dangerous
event, the tanks are inspected
using radiography and
ultrasonic testing.

76. Rail Inspection
Special cars are used to
inspect thousands of miles
of rail to find cracks that
could lead to a derailment.

77. Bridge Inspection
• The US has 578,000
highway bridges.
• Corrosion, cracking and
other damage can all
affect a bridge’s
performance.
• The collapse of the Silver
Bridge in 1967 resulted in
loss of 47 lives.
• Bridges get a visual
inspection about every 2
years.
• Some bridges are fitted
with acoustic emission
sensors that “listen” for
sounds of cracks growing.

78. NDT is used to inspect pipelines
to prevent leaks that could
damage the environment. Visual
inspection, radiography and
electromagnetic testing are some
of the NDT methods used.
Remote visual inspection using
a robotic crawler.
Radiography of weld joints.
Magnetic flux leakage inspection.
This device, known as a pig, is
placed in the pipeline and collects
data on the condition of the pipe as it
is pushed along by whatever is being
transported.
Pipeline Inspection

79. Special Measurements
Boeing employees in Philadelphia were given the
privilege of evaluating the Liberty Bell for damage
using NDT techniques. Eddy current methods were
used to measure the electrical conductivity of the
Bell's bronze casing at various points to evaluate its
uniformity.