Rockwell Hardness Testing Machine

Fabrication and overhauling of Rockwell hardness testing final year project Bsc.Mechanical Technology Engineering

1. Final Year Project Presentation Session 2013-2017 2017 Rockwell Hardness Tester Project Supervisor: Engr. Naeem-Ullah Anmol Department of Mechanical Engineering & Technology, University of Gujrat (UOG), Gujrat . 2

2. Group Members 3 Group Members Introduction 13033386-017 13033386-021 13033386-035 13033386-018 Group Leader 13033386-024 13033386-047 13033386-050

3. Presentation Contents Project introduction Motivation & Purpose Working Lever Principal Design & Components Calculation & Testing Advantages 1 2 3 4 5 6 7 4

4. Presentation Contents Limitations Applications Cost Estimation Conclusions 8 9 10 11 5

5. Introduction What is hardness?? Hardness can be defined as resistance to penetration, cutting or resistance to Plastic Deformation Measure of a material ability to resist surface indentation and scratching We use different testing methods & scales to measuring the hardness of any material

6. Introduction These are the following methods for testing the hardness of any metal: Brinell hardness testing Vicker hardness testing Rockwell hardness testing

7. Rockwell Hardness Testing The Rockwell hardness test method is a destructive type test It consists of indenting in the test material with a diamond cone or hardened steel ball indenter. The indenter is forced into the test material under applied load and make a dent inside the specimen The movement of the indenter is measure by the dial gauge and then the we calculate the hardness of material with the reading of dial gauge and applied load

8. Motivation Later there are old methods for hardness testing which does not give the accurate result due to un-specify and un- calculated load which is apply manually with hammer. Now a days, the Rockwell hardness tester is more accurate hardness tester due to the specify load apply We can test different scales in this test due to its different scales . We can get more accurate and fast testing

9. Working Rockwell Hardness tester work on the principal of lever.

10. Working The class two type lever is use:

11. Working The class two type lever is use:

12. Lever mechanism

13. Overhauling of Rockwell Machine

14. Overhauling of Rockwell Machine

15. Overhauling of hydraulic damper Disassemble the damper Change its oil seal Add lube oil inside it Assemble it again

16. Manufacturing of fulcrum Manufacturing of fulcrum upper plate in milling machine Size 4*4” Manufacturing of cone & riveting with upper plate Holes in plates according to the body puchased

17. Manufacturing of indenter lever Manufacturing of indenter lever in lathe for specific dia Size 8mm dia from bottom and 22mm from top Manufacturing of cone in milling to hold it in fulcrum upper plate

18. Overhauling of dial gauge Remove rust from the gear and shaft of dial gauge. Purchase specific designed spring for returning back of the pin Apply WD40 to moveable dial gauge

19. Painting of body and assembly of machine Remove the rust from the body and paint the body Paint all other parts of the machine and assemble it Adjust the dial gauge at its specific adjustment point Turning of the load hanger due to improper working and resize it by its facing in lathe machine Purchase the diamond indenter and fit it in machine Get final testing of a specimen

20. Design & Parts This projects consists of these main mechanical parts . Body of machine Lever & fulcrum Dial gauge Load Weights Indenter Base plate & Elevating screw Hydraulic lifter

21. Body of machine It is Made up of Cast iron and all the other equipments are fitted on it Its dimensions are: height = 24” Length = 22” Width = 5”

22. Body of machine On its bottom the hydraulic lifter and elevating screw is fit The lever mechanism is fitted on he top of the body under the dail gauge Load weights are hanged inside the center of the body with a hanger of the lever

23. Lever & fulcrum Its dimensions are length =18” Width =2” Load arm =18” Effort arm =1.5” The load was applied on the one end of this lever and the fulcrum is on another side

24. Lever & fulcrum The load arm was very near to the fulcrum and the indenter assembly also attached here to get maximum load The dial gauge also attached with the lever on the top of indenter to measure the movement of the indenter

25. Dial Gauge The dial gauge can measure the 100 th part of a mm One complete round of the short pointer indicates the movment of 1 mm The tip was attached with the lever to take measurement

26. Load Weights They are specially specified load weights Fix load = 60 kg Removeable load 1 =100kg Removeable load 2 =100kg Removeable load 3 =150kg Removeable load 4 =150kg

27. Load Weights They are attached with the opposite side of fulcrum on lever They are lifted by hydraulic lifter and release load when we apply load on specimen for indent There weight was multiplied when it is applied on indenter due to lever principle

28. Indenter The indenter is made up of high carbon steel and have the tip of industrial diamond The total load of weights are act on its tip to make dent inside the specimen

29. Indenter In A there is no load applies in indenter and we set dial gauge at zero In B & C the Load was applied and the dent was produced inside the specimen In hard material the depth of dent was less but in soft it was increse

30. Base plate & Elevating screw It is the lead screw and the base plate was fit on it Its length is 15” Its dia is 1.8” We place specimen on base plate Its working is same like screw jack We attach the specimen with indenter by the movement of elevating screw

31. Hydraulic Lifter It consists of a cylinder and Piston with lube oil filled in it Its length is 8” Its dia is 3” Its base is attached with the body of the machine The crank lever was fit its center to lift the weight upward

32. Calculations

33. Types of Test Two types of test based on load Load Rockwell Superficial Minor 10Kg 3 Kg Major 60,100,150 Kg 15,30,45 Kg

34. Rockwell Scales There are 30 different scales ,depending on the combination of the indenter and the load. 64 HRC means RHN of 64 on C- scale, (diamond indenter and 150 Kg major load) 100 HRB means RHN 100 on B-scale (1/16 inch steel ball and major load 100Kg ) 81 HR 30 N means SHN 81 on 30 N-scale (30 N diamond indenter and major load 30 Kg)

35. Dial gauge reading One revolution of the large pointer equals 1mm There are 100 divisions to a revolution Therefore ,1 division=0.01 mm Dial gauge is connected to a plunger system in the head of a tester By means of the index lever having 5:1 Therefore depth for 1 division = 0.01x0.2=0.002

36. Formula Indentation depth caused by major load HRC= 100 - -------------------------------------------------- 0.002 indentation depth caused by major load HRB= 130 - ------------------------------------------------ 0.002

37. Advantages Rockwell is the only one that allows direct reading of the hardness value without need of optical reading as per Vickers and Brinell methods The instruments working according to the Rockwell principle are the most popular, because they are less subject to operators influence Rapid test time Can be used for very wide range of material

38. Advantages The whole unit was consists on mechanical parts so there is very less chances of errors and faults The dial gauge gives the different scales for take readings due to which we can check the hardness of both soft and hard materials

39. Limitations Possibility of errors is higher owing to shifting of the sample under test load during test cycle Quality of indenter influences the test results more The tests should not be performed closer to the edge of the specimen

40. Applications Heat treatment industries: Use to check the hardness before and after hardening and annealing processes and also used to check quality of the metal before and after treatment processes. Casting industries: Use to maintain the quality of there product they insure the hardness if there

41. Applications In machining process: Check the hardness of job before doing machining of the job if it is very hard then they special type of cutting tools. Laboratories: Used for checking the strength and hardness of differents products for quality isurance

42. Cost estimation Sr. # Part / Component Rate (Rs) Quantity Amount(Rs) 1 Body 3,5000 /- 1 35,000 2 Elevating screw 3000 /- 1 3000 3 lever 4000/- 1 4000 4 Loading weights & hanger 10,000/- 1 10,000 5 Diamond Indenter 9000/- 1 9,000 6 Dial gauge 3000/- 1 3,000 7 Misc 7000/- 1 7,000 Total 71,000

43. Conclusion This project has given us a chance to learnt about the machine and its depth study We are able to assemble and disassemble the complete machine Able to diagnose the faults and remove them Product is made faster along with accuracy