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Department Of Mechanical Engineering, Faculty of Engineering Osun StatePolytechnic Iree. P.M.B 301, Nigeria 2, Department Of Mechanical Engineering, Faculty of Technology, University of Ibadan, Nigeria
-----------------------------------------------------ABSTRACT----------------------------------------------------This paper presents comparative experimental data on Mechanical Properties of Reinforced Steel produced from scrap and imported Reinforced Steel compared to International standard NO-432. Steel being part of everyday life of an individual, it is incumbent to study its physical properties so as to enable production of reliable steel bars. The Ultimate Tensile Strength (UTS), Yield Strength (YS), Breaking Strength (BS) and Hardness of steel bars manufactured from scraps and imported steel bars were investigated. Steel rods samples of 12mm and 16mm diameter were subjected to mechanical properties test using a universal testing machine. UTS, YS, BS and Hardness of the samples were obtained from the stress-strain curve plots obtained from the result data. It was observed that the locally produced steel from scrap were as good as the imported steel rods in terms of UTS, YS AND BS. Both the locally produced steel rod and imported steel rods conform with the standard in terms of yield stress but both have considerably low ultimate tensile stress compared to the standard values. The hardness values also point to the non-uniformity of the steel samples.
KEYWORDS: Reinforced Steel bar, Mechanical Properties, Comparative Study, Scrap and Imported Steel
bars --------------------------------------------------------------------------------------------------------------------------------------Date of Submission: 06 February 2014 Date of Acceptance: 15 February 2014 ---------------------------------------------------------------------------------------------------------------------------------------
I.
INTRODUCTION
Steel is an essential material for society and sustainable development; needed for people to satisfy their needs and aspirations. Steel is part of peoples everyday lives, in both the developed and developing countries. It is used in providing transportation such as automobiles and railroads, building shelters from small housing to large multi-family dwellings, construction industries, delivering energy such as electricity and natural gas, supplying water with pumps and pipelines. Steel is an iron-based material containing low amounts of carbon and alloying elements that can be made into thousands of compositions with exacting properties to meet a wide range of needs. Steel is truly a versatile material. About twenty-six different elements are used in various proportions and combinations in the manufacture of both carbon and low alloy structural steels. Some are used because they impart specific properties to the steel when they alloy with it (i.e. dissolve in the iron), or when they combine with carbon, wholly or in part, to form compounds known as carbides. Others are used because they are beneficial in ridding the steel of impurities or rendering the impurities harmless. Still another group is used to counteract harmful oxides or gases in the steel (MIT, 1999). However, all finished steel bars for reinforced work are ensured sound, free from cracks, neatly rolled to the dimension and weight as specified. Several studies have being carried out on improving the mechanical properties of steel, (Yeon et al.,2007) did a study on methods to classify defects namely; crack, dark spot and sharp mark, of steel Bar Coil (BIC) with cylindrical shape. Each of these defect was qualified serious, that can harm quality of product relatively. Hence, it is important to detect these defects on the process of production. In their own study (Hamad K.et al., 2011), investigated the hardness variation over the different diameters of the same AISI 4140 bar. Measurements were taken on the two faces of the stock at equally spaced eight sectors and fifteen layers. Statistical and graphical analyses are performed to access the distribution of hardness measurements over the specified area. Hardness value is found to have a slight decrease trend as the diameter is reduced. However, an opposite behaviour is noticed regarding the sequence of the sector indicating a non-uniform distribution over the same area either on the same face or considering the corresponding sector on the other face (cross section) of the same material bar. (Amir and Morteza, 2013), did a study and presented comparative experimental data on the mechanical
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1.
2.
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Mild Steel Grade 1 or Grade 60 For bars up to 20mm For bars above 20mm up to 50mm Mild Steel Grade II or Grade 40 For bar up to 20mm For bars above 20mm up to 50mm Medium tensile steel grade 75 For bars up 16mm For bars above 16mm up to 32mm For bars above 32mm up to 50mm
23 23 23 23 20 20 20
Source: International Standard Organization (ISC) No. 432 part 1 II. METHODOLOGY 2.1 Materials The samples used in this study were 12mm and 16mm diameter reinforced steel bars. These samples were obtained from two major sources namely: locally produced steel bars and imported steel bars. This is necessary for comparative investigation and analysis. Two specimens each of 1m length were collected on each of the diameter. The locally produced reinforced steel bars were obtained from three steel industries namely, Ife Iron and Steel (IFSM). Prism Steel rolling mill (PSM), Pheonix Steel Mill (PHSM). The imported steel samples (IM) were obtained from two different companies. A total of sixteen specimens (including imported steel) mechanical properties which includes yield strength, ultimate tensile strength, percentage elongation and hardness were investigated. 2.2 PHYSICAL REQUIREMENT All finished steel bars for reinforced work were neatly rolled to the dimension and weighted as specified and are free from defects. STEEL TESTING 2.3.1ULTIMATE TENSILE STRENGTH: This test helps in determining the maximum stress that a material can withstand while being stretched or pulled before necking, which is when the specimens cross-section starts to significantly contract. 2.3.2 YIELD STRENGTH: Yield strength is the lowest stress that produces a permanent deformation in a material. In some materials, like aluminum alloys, the point of yielding is hard to define. Thus it is usually given as the stress causing 0.2% plastic strain. This is called a 0.2% proof stress. 2.3.3 ELONGATION: The elongation is the increase in length of the gauge length, expressed as a percentage of the original length. In reporting elongation values, give both the percentage increase and the original gauge length.
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...2 Breaking Strength, BS 3 2.5 Detailed Procedure of Tensile Test The samples were turned into standard configuration using the lathe machine. Steel are cut into required length of the machine acceptability. An Instron universal Testing Machine at Engineering Materials Development Institute, Ondo Road, Akure was used in this regard. The resulting tension, load, stress and strain were measured, recorded, tabulated and plotted with the help of a control system and its associated software.
20mm
10mm
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Fig 1: A Sample of the Tested Steel 2.6 Detailed Procedure of Hardness Test The correct hardness values are beneficial for material selection and design together with material development for higher performance. Moreover, the hardness values can be used for estimating other related mechanical properties of the materials. The bottom of form shaped specimen was grounded with grinding and polishing machines with application of water in order to view the structure very well in micro hardness testing machine. The specimen was screwed into the machine and viewed through a microscope lens and left for some minute before the reading was taken.
III.
Tables 2-17 shows the results of Tensile test and the stress-strain curve plots, from the stress-strain curves it was observed that all the steel samples have low region of proportionality, hence, the high ultimate tensile stress value with the exception of PSM 16, Figs. 11 and 13, having a high proportionality limit with the least UTS value of 13842 and 13913 respectively. IFSM 12 has the highest yield stress YS values, this is obvious from the pronounced yield point in Figs. 2 and 5. The hardness result on Table 19 has some variation to point to non-uniformity of constituent steel sample, (Hamad et al, 2011). The minimum standard hardness for reinforcing steel bars can be estimated as 13.48HRC (BS4449, 1997). The result shows that PSM 12mm with the highest carbon content of 0.416%C (Ponle et al, 2014) has hardness 290.0HRC while PSM 16mm with the least carbon content has a hardness value of 232.2HRC. The trend of hardness also shows that the higher the carbon content the higher the hardness. Carbon also has negative effect on properties such as reduction in area (as well as total elongation). The trend shows that %E (elongation) decreases as carbon content increases. PSM 12mm has carbon content 0.416%C, PSM 16mm 0.112%C, IFSM 12mm 0.32%C, IFSM 16mm 0.277%C, PHSM 12mm 0.334%C, PHSM 16mm 0.194%XC, IM 12mm 0.377%C, IM 16mm 0.244%C. (Ponle et al., 2014). Increasing the carbon content produces a material with higher strength and lower ductility. It was observed that the locally produced steel from scrap were as good as the imported steel rods in terms of UTS, YS AND BS. Both the locally produced steel rod and imported steel rods conform with the standard in terms of yield stress but both have considerably low ultimate tensile stress compared to the standard values. The hardness values also point to the non-uniformity of the steel samples.
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Maximum load (N) 6040.30751 Tensile strain at Break (Standard) (mm/mm) 0.67648 Tensile extension at Yield (Zero slope) (mm) 4.24984 Load at Yield (Zero Slope) (N) 2505.52241 Tensile extension at Maximum Load (mm) 25.00218 True strain at Yield (Zero Slope) (mm/mm) 0.10954 X Intercept at Modulus (Emodulus) (mm/mm) 0.02542 Final Length (mm) 100.0000
Tensile strain at maximum load (mm/mm) 0.68107 Tensile stress at Yield (Zero Slope) (MPa) 122.65015 Tensile extension at Break (Standard) (mm) 24.83359 Load at Break (Standard) (N0 10802.50591 True strain at Break (Standard) (mm/mm) 0.51670 True stress at Yield (Zero Slope) (MPa) 136.84911 Y-Intercept at Modulus (Emodulus) (MPa) 163.144430 Diameter (mm) 5.10000
Tensile stress of maximum Load (MPa) 295.68469 Tensile Stress at Break (Standard) (MPa) 528.80347 Energy at Yield (Zero Slope) (J) 6.94453 Extension at Maximum Load (mm) 25.000218 True strain at Maximum Load (mm/mm) 0.51943 Modulus (E-modulus) (MPa) 6416.80374 Final area (cm^2)
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Maximum load (N) 6008.61050 Tensile strain at Break (Standard) (mm/mm) 0.61746 Tensile extension at Yield (Zero slope) (mm) 18.58359 Load at Yield (Zero Slope) (N) 12415.41803 Tensile extension at Maximum Load (mm) 28.97843 True strain at Yield (Zero Slope) (mm/mm) 0.49755 X Intercept at Modulus (E-modulus) (mm/mm) 0.02074 Final Length (mm) 100.0000
Tensile strain at maximum load (mm/mm) 0.61987 Tensile stress at Yield (Zero Slope) (MPa) 607.75861 Tensile extension at Break (Standard) (mm) 22.66687 Load at Break (Standard) (N0 10204.21460 True strain at Break (Standard) (mm/mm) 0.57966 True stress at Yield (Zero Slope) (MPa) 1001.50376 Y-Intercept at Modulus (Emodulus) (MPa) -38.02723 Diameter (mm) 5.10000
Tensile stress of maximum Load (MPa) 294.13306 Tensile Stress at Break (Standard) (MPa) 499.51596 Energy at Yield (Zero Slope) (J) 134.16316 Extension at Maximum Load (mm) 22.75531 True strain at Maximum Load (mm/mm) 0.58187 Modulus (E-modulus) (MPa) 1833.63876 Final area (cm^2)
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36.71000 Tensile strain at Yield (Zero Slope) (mm/mm) 0.30405 True stress at Break (Standard) (MPa)
6385.35023 Tensile strain at Break (Standard) (mm/mm) 0.88306 Tensile extension at Yield (Zero slope) (mm) 1.24984 Load at Yield (Zero Slope) (N) 689.31528 Tensile extension at Maximum Load (mm) 36.86703 True strain at Yield (Zero Slope) (mm/mm) 0.61288 X Intercept at Modulus (E-modulus) (mm/mm) -0.00119 Final Length (mm) 100.0000
1056.05626 Energy at Break (Standard) (J) 201.61466 Extension at Yield (Zero Slope) (mm) 31.25031 True stress at Maximum Load (MPa) 425.32214 Energy to X-Intercept at Modulus (E-modulus) (J)
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Fig 13: STRESS-STRAIN CURVE FOR PSM 2 16MM
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Maximum load (N) 6183.83996 Tensile strain at Break (Standard) (mm/mm) 0.65152 Tensile extension at Yield (Zero slope) (mm) 6.16656 Load at Yield (Zero Slope) (N) 1058.83703 Tensile extension at Maximum Load (mm) 29.73750 True strain at Yield (Zero Slope) (mm/mm) 0.51534 X Intercept at Modulus (E-modulus) (mm/mm) 0.03620 Final Length (mm) 100.0000
Tensile strain at maximum load (mm/mm) 0.65400 Tensile stress at Yield (Zero Slope) (MPa) 51.83211 Tensile extension at Break (Standard) (mm) 23.91734 Load at Break (Standard) (N0 10279.68600 True strain at Break (Standard) (mm/mm) 0.59105 True stress at Yield (Zero Slope) (MPa) 797.2776 Y-Intercept at Modulus (Emodulus) (MPa) -144.32005 Diameter (mm) 5.10000
Tensile stress of maximum Load (MPa) 302.71088 Tensile Stress at Break (Standard) (MPa) 503.21042 Energy at Yield (Zero Slope) (J) 3.18832 Extension at Maximum Load (mm) 24.00828 True strain at Maximum Load (mm/mm) 0.59336 Modulus (E-modulus) (MPa) 3158.15983 Final area (cm^2)
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Fig 17: STRESS-STRAIN CURVE FOR IM 2 16MM Summary of test results are presented below;
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IFSM
PHSM
PSM
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STANDARD
Table 19: HARDNESS RESULTS Sample IFMS 16mm IFMS 12mm IM 16mm IM 16mm PHSM 16mm PHSM 12mm PSM 16mm PSM 12mm 1st Reading (HRC) 242.8 284.7 301.7 295.5 269.7 256.3 229.5 290.5 2nd Reading (HRC) 247.6 289.7 300.9 300.5 267.4 258.6 234.6 288.7 3rd Reading (HRC) 240.6 288.6 294.5 298.0 272.1 260.0 232.5 290.8 Average (HRC) 243.6 287.6 299.0 298.0 269.7 258.3 232.2 290.0
IV.
CONCLUSIONS
Based on the mechanical properties experimental data obtained for the locally made steel and the imported steel rods. The following conclusions can be drawn: [1] The Nigerian locally made steel rods from recycled scraps showed the same mechanical properties as those of the imported steel rods. [2] The locally made steel and the imported steel rods showed stress values and hardness which are in conformity with the international standards; however their ultimate tensile stress steel is below the international standards. [3] The variation in the hardness of the steel rods can be rationalized based on the non-uniformity in the microstructure of the steel rods [4] Generally, there is need for proper time to time assessment of manufactured steel rod mechanical properties before any product is used for construction purposes to avoid the problem that may arise due to inconsistency.
REFERENCES
[1] Amir M. Alani, Morteza Aboutalebi, (2013). Mechanical Properties of Fibre Reinforced Concrete - A Comparative Experimental Study. World Academy of Science, Engineering and Technology. International Journal of Civil Science and Engineering. Vol. 7. No. 9. Pp 197-202 Anthony Nkem Ede. (2010), Building Collapse in Nigeria, International Journal for Civil and Environmental Vol. 10 No. 0632. British Standard, BS 449. (1997): Reinforcement bar, Jentagu Venture, www. Jentaguventure.com Hamad K. Al-Khalid, Ayman M. Alaskari and Samy E. Oraby, (2011). Hardness Variations as Affected by Bar Diameter of AISI 4140 Steel. World Academy of Science, Engineering and Technology. Vol. 51. Pp. 03-29 MIT Department of Civil and Environmental Engineering, (1999). Design of Steel Structures. Pp 1-2
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