DETAILED REPORT ON HARDNESS TEST - Amazon S3
DETAILED REPORT ON HARDNESS TEST1
Table of ContentsABSTRACT. 4INTRODUCTION . 5BRIEF INTRODUCTION ABOUT ME -: . 5MY DUTIES AND RESPONSIBILITIES AT RINE ENGINEERING PVT LIMITED,BADDI,INDIA -: . 6ABOUT UNIVERSAL TESTING MACHINE . 9COMPONENTS OF UNIVERSAL TESTING MACHINE . 9STEPS FOR USING UTM . 14OBJECTIVE . 17LITREATURE REVIEW . 17STRESS AND STRAIN RELATIONSHIP . 20YOUNG'S MODULUS, E. 22ULTIMATE TENSILE STRENGTH, ΣTS . 25FRACTURE STRENGTH, ΣF. 26TENSILE DUCTILITY . 27WORK HARDENING EXPONENT, N . 27MODULUS OF RESILIENCE, UR . 29TENSILE TOUGHNESS, UT . 29MATERIALS AND EQUIPMENT. 34EXPERIMENTAL PROCEDURE . 34TENSILE TEST EXAMPLE. 35CALCULATION FOR ALUMINUM SPECIMEN . 36THEORY . 38ABSTRACT. 39HARDNESS TEST: . 39ABOUT BRINELL HARDNESS TEST. 41COMPONENT OF BRINELL HARDNESS TESTER . 41STEPS FOR CONDUCTING HARDNESS TEST . 43OBJECTIVES . 442 Page
INTRODUCTION TO EXPERIMENT . 44PROCEDURE OF THE EXPERIMENT . 48RESULTS, COMPUTATIONS AND GRAPHWORK . 48DISCUSSION OF THE RESULTS . 49CONCLUSION. 50VICKERS HARDNESS TEST . 52THEORY . 52STEPS FOR CONDUCTING TEST . 52OBJECTIVE . 53INTRODUCTION . 53MATERIAL & METHODOLOGY . 55PROCEDURE . 56GENERAL PROCEDURE: . 56RESULTS & DISCUSSION . 57RESULTS . 57CALCULATIONS . 57DISCUSSION. 59ANSWERS FOR QUESTIONS: . 59CONCLUSION. 60LIMITATION AND ERROR OF THE EXPERIMENT . 61LIMITATIONS . 61ERRORS. 61PRECAUTIONS . 613 Page
ABSTRACTHi I am Rajesh Bain. This report by me is for giving a detailed idea of my experiences and knowledge thatI have gained while working in Rine Engineering Pvt Limited,Baddi,India from 1996 to 1997.These reports include -:1. Detailed steps required to check Ultimate tensile strength using universal testing machine ofany specimen,2. Steps to check and record Brinell hardness of specimen,3. Detailed explanation for Vicker Hardness test4. Detailed explanation to test Rockwell hardness.In this report I have tried my best to summarize all the things that I have learnt during my stay at RineEngineering Pvt Limited,Baddi,India , in simple and effective manner. After going through this reportwe can learn the steps involved in process mentioned above also learn how to extract data from thereport to make it useful practically in any firm.This report can be used as a guide to perform above mentioned test but before doing this reader shouldverify the information in these report with standard practices as mentioned in various codes books oftheir respective regions.4 Page
INTRODUCTIONBrief Introduction about Rine Engineering Pvt Limited,Baddi,IndiaRine Engineering Pvt Limited,Baddi,India is Manufacturer and supplier of customized sand and greyiron. Established in 1991 at Baddi. They are ISO 9001: 2000. JAS –ANZ and RDSO certified company.Indian railways, Bharat Heavy electrical Limited, BEML are some of their prestigious client, RigorousQuality test, and Excellent packing solutions and dimensional accuracy make them unique in theindustry. They offer wide array of steel, Grey Iron and SG Iron casting. Steel Casting Grades offered bythem are well known for their durability and reliability. They also provide steel casting that are highlyefficient. Along with that they offer steel casting for LHB bogie , They are highly instrumental inpresenting a wide spectrum of grey Iron casting to our esteemed client , Our SG Iron Casting areavailable at market leading prices.BRIEF INTRODUCTION ABOUT ME -:5 Page
MY DUTIES AND RESPONSIBILITIES AT RINE ENGINEERING PVTLIMITED,BADDI,INDIA -:At Rine Engineering Pvt Limited,Baddi,India I was appointed as Quality control engineer and my dutieswere as follows -:Analyze process quality performance data for company facilities and provideguidance/input into performance improvementsTo check & record Ultimate tensile strength using Universal testing machine (UTM) ofspecimen/sample castings after annealing.To check & record the Brinell Hardness (BHN) of specimen/sample castingsafter annealing. The load is applied manually and the indentation is read with the help ofa Brinell Microscope.I have used Rockwell & Vickers hardness testing techniques also in some cases to checkthe hardness of sample castingsPerform internal audits with the objective to help plant find and correct quality gapsInvestigation and problem solving through root cause analysis for internal and externalquality concerns with focus on permanent corrective actionsEnsure all products are manufactured in compliance with customer specifications, safetystandards and design specifications. Recommend corrective actions necessary to ensureconformity with specifications and standards.Ensure Corporate Quality processes are followed.Drive quality improvements utilizing root cause analysis, process reviews andimprovements, corrective actions, statistical process control, in-process and finalinspections, control gauges and test equipment, quality plans and overall qualitycommunications.6 Page
Evaluate and determine disposition of non-conforming materials and formulatecorrective actions.Communicate with customer service, supplier quality, production engineering andmanufacturing personnel/management7 Page
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ABOUT UNIVERSAL TESTING MACHINEA universal testing machine (UTM), also known as a universal tester , materials testingmachine or materials test frame, is used to test the tensile strength and compressivestrength of materials. It is named after the fact that it can perform many standard tensile andcompression tests on materials, components, and structures.COMPONENTS OF UNIVERSAL TESTING MACHINELoad frame - Usually consisting of two strong supports for the machine. Some smallMachines have a single support.Figure – Load frame of UTM9 Page
Load cell - A force transducer or other means of measuring the load is required.Periodic calibration is usually required by governing regulations or quality system.Figure – Load cell of UTMCross head - A movable cross head (crosshead) is controlled to move up or down. Usuallythis is at a constant speed: sometimes called a constant rate of extension (CRE) machine.Some machines can program the crosshead speed or conduct cyclical testing, testing atconstant force, testing at constant deformation, etc. Electromechanical, servo-hydraulic,linear drive and resonance drive are used.Figure – Cross head of UTM10 P a g e
Means of measuring extension or deformation - Many tests require a measure of theresponse of the test specimen to the movement of the cross head. Extensometers aresometimes used.Figure- Extensometer11 P a g e
Output device - A means of providing the test result is needed. Some older machineshave dial or digital displays and chart recorders. Many newer machines have a computerinterface for analysis and printing.Figure – Output device12 P a g e
Conditioning - Many tests require controlled conditioning (temperature, humidity,pressure, etc.). The machine can be in a controlled room or a special environmentalchamber can be placed around the test specimen for the test.Figure – Room for UTMTest fixtures, specimen holding jaws, and related sample making equipment are called forin many test methods.13 P a g e
STEPS FOR USING UTMThe set-up and usage are detailed in a test method, often published by a standardsorganization. This specifies the sample preparation, fixturing, gauge length (the lengthwhich is under study or observation), analysis, etc. In India Bureau of Indian Standardpublishes IS 1828-1 (2002), IS 1828-2 (2002) and ISO 5893 Rubber and plastics testequipment - Tensile, flexural and compression types (constant rate of traverse) –Specification for this purpose.The specimen is placed in the machine between the grips and an extensometer ifrequired can automatically record the change in gauge length during the test. If anextensometer is not fitted, the machine itself can record the displacement between itscross heads on which the specimen is held. However, this method not only records thechange in length of the specimen but also all other extending / elastic components of thetesting machine and its drive systems including any slipping of the specimen in the grips.Once the machine is started it begins to apply an increasing load on specimen.Throughout the tests the control system and its associated software record the load andextension or compression of the specimen.Machines range from very small table top systems to ones with over 53 MN (12million lbf) capacities14 P a g e
SOME GENERAL SPECIFICATION OF UTM-MODELUTN-10UTN-20UTN-40UTN-60UTN-100 UTN-200UTN300Maximum capacitykN1002004006001000200030001st Measuring um GraduationskN0.20.4112452nd Measuring RangekN0.500-1000-2000-3000-5000-10000-1500Minimum GraduationskN0.10.20.50.5122.53rd Measuring RangekN0.250-500-1000-1200-2500-5000-600Minimum GraduationskN0.050.10.250.20.5114th Measuring RangekN0.100-200-400-600-1000-2000-300Minimum ce for tensile atfully descendedworking pistonmmClearance forcompression test at fullydescended workingpistonClearance betweencolumnsRam strokemm/minStraining/piston speeds(at no load)CONNECTED 8.54004403-L X W X H (approx.)mm2032 x750 x1960 x2032 x750 x1960 x2060 x750 x2180 x2065 x750 x2534 x2415 x815 x2900 x3000 x1200 x3600 x3500 x1900 x4550 xWeight approx.kg1500150025003500550012 50022 000STANDARDACCESSORIESFOR TENSION TESTClampings jaws for flatspecimens diameter15 P a g 0-7070-90
Clampings jaws for flatspecimensthickness widthmmFOE COMPRESSIONTESTmmPair of compressionplates of diametermmFOR TRANSVERSE TEST ameter of rollersmm30303050507070Maximum clearancebetween supportsmm5005005006008009001000mm6,126,1212, 1616, 2216, 2230, 4050, 75Table with adjustablerollers width of rollersRadius of punch tops16 P a g e
OBJECTIVE Although UTM can be used for many purpose but my main objective in firm was to uniaxial testing ofthe test specimen to get the ultimate tensile strength of the specimen. To get load extension and stress strain graph for the materials to be tested. To evaluate the values of ultimate tensile strength, yield strength, % elongation, fracture strain andYoung's Modulus of the selected metals when subjected to uniaxial tensile loading. To study the deformation and fracture characteristics of different materials such as aluminum, steelsor brass when subjected to uniaxial tensile loading.LITREATURE REVIEWUNIAXIAL TENSILE TESTINGUniaxial tensile test is known as a basic and universal engineering test to achieve material parameterssuch as ultimate strength, yield strength, % elongation, % area of reduction and Young's modulus. Theseimportant parameters obtained from the standard tensile testing are useful for the selection ofengineering materials for any applications required. The tensile testing is carried out by applyinglongitudinal or axial load at a specific extension rate to a standard tensile specimen with knowndimensions (gauge length and cross sectional area perpendicular to the load direction) till failure. Theapplied tensile load and extension are recorded during the test for the calculation of stress and strain. Arange of universal standards provided by Professional societies such as American Society of Testing andMaterials (ASTM), British standard, JIS standard and DIN standard provides testing are selected based onpreferential uses. Each standard may contain a variety of test standards suitable for different materials,dimensions and fabrication history. For instance, ASTM E8: is a standard test method for tension testingof metallic materials and ASTM B557 is standard test methods of tension testing wronght and cast17 P a g e
aluminum and magnesium alloy products A standard specimen is prepared in a round or a squaresection along the gauge length as shown in figures respectively, depending on the standard used.Figure – Standard specimenBoth ends of the specimens should have sufficient length and a surface condition such that they arefirmly gripped during testing. The initial gauge length Lo is standardized (in several countries) and varieswith the diameter (Do ) or the cross-sectional area (Ao ) of the specimen as listed in table 1.Type specimenUnited StateGreat SheetRodTable 1This is because if the gauge length is too long, the % elongation might be underestimated in this case.Any heat treatments should be applied on to the specimen prior to machining to produce the finalspecimen readily for testing. This has been done to prevent surface oxide scales that might act as stress18 P a g e
concentration which might subsequently affect the final tensile properties due to premature failure.There might be some exceptions, for examples, surface hardening or surface coating on the materials.These processes should be employed after specimen machining in order to obtain the tensile propertiesresults which include the actual specimen surface conditions.Dimensional relationships of tensile specimens used in different countries. The equipment used fortensile testing ranges from simple devices to complicated controlled systems. The so-called universaltesting machines are commonly used, which are driven by mechanical screw o
Brief Introduction about Rine Engineering Pvt Limited,Baddi,India Rine Engineering Pvt Limited,Baddi,India is Manufacturer and supplier of customized sand and grey iron. Established in 1991 at Baddi. They
This standard covers hardness conversions for metals and the relationship among Brinell hardness, Vick-ers hardness, Rockwell hardness, Superficial hardness, Knoop hardness, Scleroscope hardness and Leeb hardness. ASTM E10 (Brinell) This standard covers the Brinell test method as used by stationary, typically bench-top machines. This
1. Define Hardness. 2. Applications of Rockwell Hardness A Scale, B-Scale, C-Scale. 3. Type of Indentor used in the Three Different Scales of Rockwell Hardness Test. 4. Different Types of Hardness Testing Methods. 5. Size of the Ball to be used in Ball Indentor of Rockwell Hardness Test. 6. Di ameters of the different Balls used in Brinell Hardness Test.
Vickers hardness test (HV), which has one of the widest scales Brinell hardness test (HB) Knoop hardness test (HK), for measurement over small areas Janka hardness test, for wood The Janka Side Hardness test measures the force required to press an 11.28mm (0.444 inch) steel ball to half its diameter cross-grain into a block of wood.
1. ROCKWELL HARDNESS TEST 1. AIM: To determine the Rockwell Hardness of a given test specimen II. APPARATUS: Rockwell Hardness testing machine, Test specimen. III. THEORY: HARDNESS- It is defined as the resistance of a metal to plastic deformation against Indentation, scratching, abrasion of cutting. The hardness of a material by this Rockwell .File Size: 860KB
g acceleration constant, 9.81m/s2 H nano, micro, macrohardness, kg/mm2,GPa HB Brinell hardness number, kg/mm2,GPa HBGM geometric mean of minimum and maximum Brinell hardness, kg/mm2,GPa HBK Berkovich hardness number, kg/mm2,GPa HK Knoop hardness number, kg/mm2,GPa HM Meyer hardness number, kg/mm2,GPa HRC Rockwell C hardness
A Leeb’s Hardness Tester measures the hardness of sample material in terms of Hardness Leeb (HL), which can be converted into other Hardness units (Rockwell B and C, Vicker, Brinell and Shore D). 1.3. Notation of Leeb’s Hardness When measuring the hardness of a sample materi
Using standard hardness conversion tables, the Rockwell hardness value is determined for the load applied, the diameter of the indenter, and the indentation depth. The hardness testing of plastics is most commonly measured by the Rockwell hardness test or Shore (Durometer D) hardness tes
inspection qualified Leeb hardness tester and corresponding hardness tester to test at the same sample respectively. For each hardness value, each measure homogeneously 5 points of Leeb hardness value in the surrounding of more than three indentations which need conversion hardness, using
