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ROCKWELL HARDNESS TEST

Aim To determine the hardness of the given metal specimen by Rockwell hardness test.

Materials and equipments required Rockwell hardness testing machine Black diamond cone / Ball indenter Metal specimen

Theory Rockwell test is developed by the Wilson instrument co U.S.A in 1920. This test is an indentation test used to find the hardness of hard and very hard materials. For hard materials like mild steel, brass and aluminium, the indenter used is hard steel ball indenter. The diameter of the ball in the ball indenter is 1/16. The load applied for these materials is 100 kg and the time of application is 5 to 6 seconds. For very hard materials like hardened steel and tool steel, diamond cone indenter is used. The apex angle in cone indenter is 120. The cone is made of industrial diamond. The load to be applied is 150 kg and the time of application is 6 to 8 seconds.

Precautions 1. Thickness of the specimen should not be less than 8 times the depth of indentation to avoid the deformation to be extended to the opposite surface of a specimen. 2. Indentation should not be made nearer to the edge of a specimen to avoid unnecessary concentration of stresses. In such case distance from the edge to the center of indentation should be greater than 2.5 times diameter of indentation. 3. Rapid rate of applying load should be avoided. Load applied on the ball may rise a little because of its sudden action. Also rapidly applied load will restrict plastic flow of a material, which produces effect on size of indentation.

Procedure 1. Examine hardness testing machine 2. Depending on the material of the specimen select the type of indent and the corresponding load.

3. Place the specimen on platform of a machine. Using the elevating screw raise the platform and bring the specimen just in contact with the ball. Apply an initial load until the small pointer shows red mark. 4. After the pointer in the dial comes to rest, note down the Rockwell Hardness Number from the scale, corresponding to the type of indent, in the dial. 5. Repeat the procedure five times on the specimen selecting different points for indentation.

BRINELL HARDNESS TEST

Aim To determine the hardness of the given metal specimen by Brinell hardness test.

Materials and equipments required Brinell hardness testing machine Ball indenter Metal specimen Brinell microscope

Theory Hardness is basically an important mechanical property of the metals and is defined as the resistance given by metal specimen to indentation, scratching or abrasion on its surface. Brinell hardness is a method of finding hardness of given specimen by indentation and was introduced by J.A.Brinell in 1900. This method uses a steel ball indenter. The hardness number is then calculated from the depth of the indentation produced by the load applied. Thus, it is an indirect method of finding hardness. Brinell hardness can be defined as the ratio of the load applied to the spherical area of the indentation formed on the specimen surface and is calculated in terms of kgf/mm2.

Formula Used Brinell Hardness Number (BHN) =

=
(

))

where P Applied force in kgf d Diameter of indentation in mm D Diameter of indenter in mm

Precautions 1. Thickness of the specimen should not be less than 8 times the depth of indentation to avoid the deformation to be extended to the opposite surface of a specimen.

2. Indentation should not be made nearer to the edge of a specimen to avoid unnecessary concentration of stresses. In such case distance from the edge to the center of indentation should be greater than 2.5 times diameter of indentation. 3. Rapid rate of applying load should be avoided. Load applied on the ball may rise a little because of its sudden action. Also rapidly applied load will restrict plastic flow of a material, which produces effect on size of indentation.

Procedure 1. Place the specimen on the anvil of the machine. 2. Depending on the specimen material and the diameter of the ball indenter, select the proper load. Select a load of 3000 kgf and a steel ball indenter of 10 mm diameter for hard material like steel. Select a load of 1500 kgf and a stell ball indenter of 10 mm for soft material(aluminium and brass). Duration of loading is 10 seconds for hard material and 30 seconds for soft materials. 3. Insert the ball indenter in the holder. 4. Rotate the anvil and bring the specimen in contact with the indenter. 5. Apply the load for the specified time. 6. Release the load and remove the specimen from the anvil. 7. Measure the diameter of the impression made by the indenter using Brinell microscope. 8. Repeat the same procedure and take two readings for each specimen.

IZOD IMPACT TEST

Aim To determine the impact strength of steel by Izod impact test.

Materials and equipments required Impact testing machine Steel specimen (75 mm x 10 mm x 10 mm) Theory An impact test signifies toughness of material that is the ability of material to absorb energy during plastic deformation. Static tension tests of unnotched specimens do not always reveal the susceptibility of a metal to brittle fracture. This important factor is determined by impact test. Toughness takes into account both the strength and ductility of the material. Several engineering materials have to withstand impact or suddenly applied loads while in service. Impact strengths are generally lower as compared to strengths achieved under slowly applied loads. Of all types of impact tests, the notch bar tests are most extensively used. Therefore, the impact test measures the energy necessary to fracture a standard notch bar by applying an impulse load. Also, the test measures the notch toughness of material under shock loading. Values obtained from these tests are not of much use to design problems directly and are highly arbitrary. Still it is important to note that it provides a good way of comparing toughness of various materials or toughness of the same material under different condition. This test can also be used to assess the ductile brittle transition temperature of the material occurring due to lowering of temperature.

Formula Used

Impact strength of the specimen =

I = Where E2 strain energy absorbed during free swing in J E1 strain energy absorbed during fracture swing in J A Area of resisting section in mm2

Precautions

1. Pendulum must swing freely over the horizontal axis of rotation. 2. Friction effects must be accounted for. 3. Operator should not stand inside the swinging zone of the pendulum. 4. Only standard pendulum must be used.

Procedure 1. Set the pointer to the maximum reading of the dial. 2. Release the lock and allow the pendulum to swing. 3. Record the energy absorbed during free swing, which is indicated by the pointer on the dial. Let it be E1. 4. Lock the pendulum in its original position. 5. Keep the specimen secured vertically in the vice such that the notch in the specimen is facing the hammer. 6. Release the lock and allow the striking edge of the pendulum to strike the specimen. 7. The reading shown in the dial is the energy absorbed by the specimen during the fracture. Let it be E2. 8. Impact strength of the specimen is calculated using the above mentioned formula.

CHARPY IMPACT TEST

Aim To determine the impact strength of steel by Charpy impact test.

Materials and equipments required Impact testing machine Steel specimen (75 mm x 10 mm x 10 mm) Theory An impact test signifies toughness of material that is the ability of material to absorb energy during plastic deformation. Static tension tests of unnotched specimens do not always reveal the susceptibility of a metal to brittle fracture. This important factor is determined by impact test. Toughness takes into account both the strength and ductility of the material. Several engineering materials have to withstand impact or suddenly applied loads while in service. Impact strengths are generally lower as compared to strengths achieved under slowly applied loads. Of all types of impact tests, the notch bar tests are most extensively used. Therefore, the impact test measures the energy necessary to fracture a standard notch bar by applying an impulse load. Also, the test measures the notch toughness of material under shock loading. Values obtained from these tests are not of much use to design problems directly and are highly arbitrary. Still it is important to note that it provides a good way of comparing toughness of various materials or toughness of the same material under different condition. This test can also be used to assess the ductile brittle transition temperature of the material occurring due to lowering of temperature.

Formula Used

Impact strength of the specimen =

I = Where E2 strain energy absorbed during free swing in J E1 strain energy absorbed during fracture swing in J A Area of resisting section in mm2

Precautions

1. Pendulum must swing freely over the horizontal axis of rotation. 2. Friction effects must be accounted for. 3. Operator should not stand inside the swinging zone of the pendulum. 4. Only standard pendulum must be used.

Procedure 1. Set the pointer to the minimum reading of the dial. 2. Release the lock and allow the pendulum to swing. 3. Record the energy absorbed during free swing, which is indicated by the pointer on the dial. Let it be E1. 4. Lock the pendulum in its original position. 5. Keep the specimen secured vertically in the vice such that the notch in the specimen is kept on the opposite side of blow. 6. Release the lock and allow the striking edge of the pendulum to strike the specimen. 7. The reading shown in the dial is the energy absorbed by the specimen during the fracture. Let it be E2. 8. Impact strength of the specimen is calculated using the above mentioned formula.

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