Rockwell Tester 200HRS-150 MFR User Guide
Transcript of Rockwell Tester 200HRS-150 MFR User Guide
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I. Introduction
1. General information
Hardness is an important parameter of mechanical properties for metallic and alloyed
materials. Usually it refers to the capacity of the material to resist against another harder
material of certain shape and size to be pressed into its surface without any residual
deformation by itself.
Rockwell hardness test is a test method which is the rapidest, most convenient and
economy among all the tests of mechanical properties. Besides high testing efficiency
and simple operation, it also features that the hardness values could be obtained directly,
which enables it to accomplish the testing which other tests fail.
The Model 200HRS-150 Digital Display Rockwell Hardness Tester is designed and
manufactured according to the state standard Metallic Rockwell Hardness Test
GB/T230.1-2004. It can be used for measuring Rockwell hardness of hard alloys,
quenched steel and unquenched steels in the laboratories of factories, research
institutions and colleges.
2. Principle of Test
Fig-1 Principle of Rockwell Hardness Test
Rockwell hardness test is to apply diamond cone indenter (see Fig-2) or steel ball
indenter (see Fig-3) to the specimen surface in two steps as shown in Fig-1, which shall
be retained for a certain period of time, and measure the residual indentation depth under
preliminary test force after the main test force is removed. The Rockwell hardness is
calculated by formula (1) as per the h value, the constant N and S (see Table 1).
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Rockwell hardness value = Nh/S Formula (1)
Table 1 Symbols and Descriptions
Symbols Descriptions Units
F0 Preliminary test force N
F1 Main test force N
F Total test force N
S Unit of given scale mm
N Hardness value of given scale
h Residual indentation depth under preliminary
test force after main test force is removed mm
HRA
HRCRockwell hardness = 100h/0.002
HRB Rockwell hardness = 130h/0.002
1----Indentation depth under preliminary test force F0;
2----Indentation depth under main test force F1;
3----Depth of elastic come-back after main test force F1 is removed;
4----Residual indentation depth h;
5----Specimen surface
6----Measurement datum;
7----Position of indenter.
Example: 59HRC indicates that Rockwell hardness is 59 measured by C scale.
* The above content is referred to the state standardMetallic Rockwell Hardness Test
GB/T230.1-2004
3. Range of Application
As per hardness range and size of the specimen, different indenters and loads can be
selected and the hardness values can be indicated by different scale such as A, B and C
scales for Rockwell hardness. The loads, indenters, values of the constant K and ranges
of application are shown in Table 2.
l Scale A is used to measure the metallic materials whose hardness exceed 67HRC,such as tungsten carbide, hard alloy, hard thin slabs and surface hardened parts. The
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range of measurement is 2085HRA.
l Scale B is used to measure the lower-hardness parts whose range of hardness shallbe 25100 HRB, such as non-ferrous metal and its alloy, annealed steel, etc. If the
hardness of specimen is smaller than 25HRB, the metal will begin to creep, creep
deformation will last a long time and the result will be inaccurate. If the hardness of
specimen is larger than 100HRB, error will happen since the steel ball indenter is
prone to deform and the depth of indentation is too small.
l Scale C is used for hardness test of specimen which is quenched or tempered, suchas carbide steel, tool steel and alloyed steel. The range of measurement shall be
2067 HRC. If the hardness of specimen is lower than 20HRC, the measurement is
incorrect since it is too deep for the diamond indenter to penetrate into the specimen
and the error will increase caused by the geometric shape of the indenter. If the
hardness of specimen is larger than 67HRC, the diamond is easy to damage due to
the large pressure produced by the sharp tip of the indenter.
Fig-2 Diamond cone indenter Fig-3 Steel ball indenter
Table 2 Usual scales for Rockwell Hardness
Test force (kgf) ConstantScale Indenter (mm)F0 F1 F N
Application examples
A Diamond cone indenter 10 50 60 100 Hard metal and alloy
BSteel ball indenter
(1.588mm)10 90 100 130
Non-ferrous and soft
metal
C Diamond cone indenter 10 140 150 100Structural and tool
steel
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4. Technical Parameters
Please refer to Table 3 and Fig-4 for main technical parameters.
Table 3 Main Technical Parameters
Itemcode Content
HeightH 729mm
WidthW 225mm
LengthL 522mm
Maximum height of specimen (with sleeve)B 140mm
Maximum height of specimen (without sleeve)B 210mm
Depth of throat (A) 165mm
Net weight 98Kg
Power supply 110 / 220V, 50Hz
Reference
ScalesRange of Harness Reading Allowance
20HRA~75 HRA 2 HRA
A
>75HRA~88 HRA 1.5 HRA
20HRB~45HRB 4HRB
>45HRB~80HRB 3HRBB
>80HRB~100 HRB 2 HRB
C 20HRC~70HRC 1.5HRC
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Fig-4 Schematic Diagram of Overall Dimensions
5. Descriptions of Mechanism Parts
This tester is composed of machine body (1), indenter (27), loading and unloading
mechanism (10, 19), measuring mechanism (8), specimen support mechanism (5) and so
on (See Fig-5).
The test forces are applied onto the main axis by the combination of weights and
lever, which is magnified. That is to say, the test forces are magnified by the larger lever
and pressed onto the surfaces of specimen. At the same time when the indenter is pressed
into the specimen, the vertical displacements of main axis are passed to the reading
device through measuring lever, showing the hardness value as a result.
l The machine body (1) is the shell of the tester, which accommodates othercomponents directly or indirectly. Except the worktable (5), screw rod (4) andelevating handle (2), all the other parts are fitted inside the shell.
l Total test forces are composed of main test forces and preliminary test forces. Thepreliminary test force is produced by the self weight of the larger lever (10) and main
shaft (7). The main test force is obtained with weight (19) hanging on the larger lever
via hoist ring (15) as per Lever Principle.
l The upper end face of the indenter (27) shall carry the total test force while its sharpend is pressed into the surface of the specimen.
l To select different weights and combine them in different group to obtain required
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total test forces including 588N/60Kgf, 980N/100Kgf and 1470N/150Kgf,
l Loading and unloading mechanism is composed of motor and roller wheel. Themotor drives the roller wheel so that the support rod could be elevated, which
realizes the loading and unloading.
l Test results could be read out from the front display (17) of measuring mechanism.l Specimen support mechanism is composed of worktable (5) and screw rod (4) to
carry the hardness block or the specimen to be tested.
Fig-5 Schematic Diagram of mechanical parts
1.Machine body 2. Elevating handle 3. Elevating hand wheel4. Screw rod sleeve (with screw rod inside) 5. Worktable 6. Specimen to be tested
7. Main shaft 8. Sensor 9. Smaller lever 10. Larger lever 11. Electric control
12. Upper cover 13. Compensation block 14. Location mark 15. Hoist ring
16. Screw 17. Front display 18. Rear shield 19. Weight
20. Weights changeover support 21. Loading and unloading mechanism 22. Motor
23. on/off switch 24. Foundation screw 25. Printer 26. Load changeover handle27. Indenter
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II. Package Opening, Transportation, installation and Commissioning
1. Preparation
l The tester should be placed indoors, dry and clean and free from corrosive gases.l The tester should be placed indoors, free from foreign mechanical vibration.l Ambient temperature should be kept between 10-30C.l The test stand should be of cement or metal, with certain strength and stiffness so as
to carry over the hardness tester and its accessories. The plane surface should be made
same as shown in Fig-6 (the dimensions in the following figure is for reference only),
with a 70mm hole for the screw rod to pass through. The levelness should be
controlled within 0.2/1000.
l Adequate space should be reserved around the tester for the sake of installation,maintenance and commissioning.
Fig-6 Schematic Diagram of Test Stand
2. Package opening
1) Remove the packing belt around the package box, as shown in Fig-7.2) Remove the wood screw fixing the packing box to the bottom seat and lift up the
packing box.
3) Find the document bag and inspect the contents inside, including the OperationManual, Packing List and Quality Certificate.
4) Loosen the nut on the package hook fastening the box of accessory by the spanner,take down the package hook and box of accessory. Sort out the objects inside the boxand verify whether all the parts contained in the packing list are available.
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5) Remove the dust-proof cover.6) Remove the four foundation bolts fastening the tester onto the bottom seat of package
box by the spanners.
7) Remove the printer bound on the tester.
Fig-7 Schematic Diagram of Box Opening
3. Cautions for transportation
l Dont try to move the tester by yourself, or it may lead to damage to the tester orpersonal injury since the tester is heavy. Only with two or more than 2 experienced
people can the tester be moved.l During transportation, the slant of the axial line between the indenter and the screw
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rod should not be over 15 against the vertical line.
l During the transportation, the contacts between the operators and the tester are limitedto the plane C, D, E and F. Never touch the planes other than the aforesaid and other
parts in order not to influence the accuracy (Fig-4)
l The tester should be handled with care to avoid any impact or collision.4. Installation and commissioning
Before the installation, please make ready the tools such as spanner, level meter and
larger flat anvil, etc.
1) Place the tester onto the prefabricated test stand in a way that the screw rod fallsthrough the hole reserved. Fetch out the 4 foundation bolts (24) from accessory box
and fit them into the threaded holes on the bottom of tester.
2) Loosen the screws on the upper cover and rear shield, and remove the upper cover andrear shield.
Fig-8 Removing the binding rope of larger lever
3) Remove the binding rope of larger lever (10), as shown in Fig-8.4) Remove the binding rope of smaller lever (9), as shown in Fig-9.5) Take out the weights from accessory box and mount them on the end of larger lever.
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Fig-9 Removing the binding rope
6) Turn the elevating handle anticlockwise to let the screw rod coming downwards, andthen remove the protective cushion block for the indenter (Fig-10). In case that the
screw rod does not come down and the handle rises up with the screw rod when the
handle is turned, the protection block could not be removed. This is because the screw
rod and its seating are bonded together during the transportation. The best way is to
turn the handle anticlockwise to life up the hand wheel 20mm, and then press with
force down the hand wheel, and then the screw rod and its seating would be
disengaged.
Fig-10 Removing protective cushion block of indenter
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7) Remove the protective sleeve, clean the antirust grease on the screw rod and elevatingscrew with kerosene, fill some lubricants into the contacts between screw rod and
elevating nut and put back the protective sleeve.
8) Fetch the anvil from the accessory box and put it on top of the screw rod. Adjust thelevelness with a level meter to be within 0.2/1000. If necessary, adjust the four
foundation screws at the bottom of the instrument to make the tester is in good
levelness.
9) Put back the upper cover and rear shield.10)Connect the ground wire and insert the power plug into the power socket.III. Normal Operation
Before operation, the kind of reference scale should be determined subject to
different specimen. Except otherwise specified, the following operation is based on
Reference Scale C, i.e. using diamond cone indenter and total test force 150Kgf.
1. Preparation prior to normal operation
To be well versed with the functions of front and rear panel.
l Front Panel
Fig-11 Schematic Diagram of Front Panel
1) RESET: resume to initial status
2) CLEAR: to zero the displacement value
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3) ESC: to cancel one event being carried on.
4) SCALE: This button is actuated only when the number of times is zero under
measurement status. Then by pressing this button, the Scale, test force and indenter
will be brightened, which means that current status is scale selection. Press UP or
DOWN arrow key to select required scale.
5) DEL.: If the measured hardness value is beyond the preset maximum or minimum
value, the system will give out beeping sound. Here, the measured value could be
deleted by pressing this button. If not pressing this button, lower down the screw rod
and the beeping will disappear, and the measured value is valid.
6) MAN.: When the tester is turned on, at this moment, by pressing and then releasing
this button, the tester will enter Manual force measurement status.
7) LOAD: After the tester enters manual force measurement status, let the screw rod rise
up, then the screen will display the displacement of the sensor. Pressing this button
and releasing it, the tester will enter into force measurement status, and start to load,
retain the load, unload and display the hardness value.
8) MENU: This button could be started only when the number of times is zero at
measurement status. The tester will enter the setup interface by pressing this button, 5
items in total.
To select corresponding item by pressing UP or DOWN key, press OK to enter
into Preset Menu and press ESC to return back to Measurement status.
a. At HARDNESS CONVERSION, the scales could be selected by LEFT or RIGHT
arrow key. Press OK for confirmation or press ESC to return.
b. DWELL TIME means to select the load retaining time between 2-99 seconds.
Press LEFT or RIGHT key to increase or decrease the load retaining time. By
holding the LEFT or RIGHT arrow key, the figures could be decreased or
increased rapidly and continuously. And then press OK for confirmation or ESC toreturn.
c. LIMITS: to set up lower limit and upper limit by pressing UP arrow key to
changeover the selection and pressing LEFT or RIGHT key to preset the figures.
By holding the LEFT or RIGHT arrow key, the figures could be decreased or
increased rapidly and continuously. And then press OK button for confirmation or
ESC to return.
d. PRINTER: to preset the printing status. The selections could be shifted by pressingUP or DOWN arrow key. Then press OK for confirmation or ESC to return.
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e. TEST NUMBER: to preset test numbers within 2 to 99 by pressing LEFT or
RIGHT key. By holding the LEFT or RIGHT arrow key, the figures could be
decreased or increased rapidly and continuously. And then press OK for
confirmation or ESC to return.
l Rear panel includes power switch, printer interface, fuse and power socket, as shownin Fig-12.
Fig-12 Schematic Diagram of Rear Panel
l Other preparations1) Presetting test forces: to turn the load changeover handle, as shown in Fig-13, the
wordings such as 1470N, 980N, 588N could be seen at the handle.
Fig-13 Presetting test forces
2) Fitting indenter (Fig-14)
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The steel ball indenter is mounted on main shaft before delivery. To re-mount the
other indenter, please operate as follows:
a. Fit the indenter into the hole of main shaft.b. Ensure the end face of indenter is pressed tightly against the end face of main shaft,
and then tighten the screw.
Fig-14 Fitting the indenter
3) Adjustment of retaining time of total test force: As per the state standard Metal
Rockwell Hardness Test GB/T230.1-2004, the retaining time of total test force
should be 42 S. As for low hardness materials, the retaining time could be extended.
The allowance is 2 S.
4) The specimen should meet the following requirements:
a. The specimen should be of certain sizes and thickness. Both the distance ofcenters of two adjacent indentations and distance between the center of
indentations and the edge of specimen should be more than 3mm. The minimum
thickness of specimen shall be more than 8 times of the depth of indentation. After
the test, no obvious deformation should be observed at the support surface of the
specimen. The minimum thickness is subject to the quality of materials and the
load applied. For details, please refer to Table 4.
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Table 4 Minimum Thickness
b. The surface to be tested should be flat plane. In case of curved plane, the testresults shall be corrected if the radius is small. The amount of correction of
cylindrical specimen is included in Table 5 and Table 6.
c. The surfaces of specimens should be fine polished or grinded, the roughness shallbe up to no less than . However, the processing should not change the
hardness, i.e., no hardening or tempering. The roughness of supporting surface
shall be no less than . The tested surface, the supporting surface and the
worktable should be kept clean. The specimen should be placed on the worktable
stably without any movement during the testing.
d. The specimens shall be placed to ensure that the test force is applied perpendicularto the surface to be measured. As for specimens with curved shape or other
abnormal shapes, corresponding anvil and proper position of measurement should
be selected. For example, V-shaped anvil should be used for cylindrical specimens.
Those with hollow cavity shall be alert of deformation caused by the applied test
force, otherwise the measured hardness values wont be correct.
5) To presetting of scales, printer, upper and lower limit, load retaining time and numbers
of test shall be predetermined as per specific requirement.
ScalesHardness
HR
Min.
thickness
mm
ScalesHardness
HR
Min.
Thickness
mm
70 0.7 80 1.0
80 0.5 90 0.8A
90 0.4
B
100 0.7
25 2.0 20 1.5
30 1.9 30 1.3
40 1.7 40 1.2
50 1.5 50 1.0
60 1.3 60 0.8
B
70 1.2
C
70 0.7
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2. Testing Procedures
1) Turn power on (Fig-12), the LCD display screen will light up.2) At the main menu as shown in Fig-15: When the test number is zero, press SCALE
key to enter the interface of scale selecting. Change the scales by pressing UP and
DOWN arrow Key.
Fig-15 Main Menu Fig-16 Setup interface
3) When the test number is zero, press MENU key to enter the setup interface (seeFig-16). The conversion scale, printer, upper and lower limit, load retaining time,
number of tests and language can be preset, as shown in Fig-17-18-19-20-21-22.
Fig-17 Scale Shift Fig-18 Load Retaining Time
Fig-19 Upper and Lower Limits Fig-20 Printer
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Fig-21 Number of tests Fig-22 Language Selection
Fig-23 Testing interface
4) Clean the top face of screw rod and the end faces of test anvil, then place the anvil into
the reserved holes of screw rod. The type of anvil shall be selected as per the
dimensions of specimen.
5) Clean the support surface clean and then put the specimen onto the anvil. Turn
clockwise the elevating handle slowly to let the screw rod rise up. As soon as theindenter touches the specimen, turn the handle even more slowly and stably, and the
light band on the screen will move from PRELOAD to OK, which means the
preliminary load 98N has been applied. Herein, stop turning the elevating handle at
once, (otherwise the light band will enter into the OVER and the system will give out
warning noise and the test shall be regarded invalid. In this case, turn the elevating
handle anticlockwise to let the screw rod descend until the light band disappears and
the indenter is not in touch with the surface of specimen). At the same time, the motor
will run to automatically apply the main test force, retain the test force and remove it.
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This is the start of automatic testing and the system will shift from LOAD, DWELL
and UNLOAD, and finally displays the hardness value and corresponding hardness
value of different scale. Fig-23 shows the measured hardness value at the fifth test.
The measured value is 62.2HRC and the repeatability is 0.2. In case that the total
number of tests is five, the result for the first test will be omitted. If upper and lower
limits are preset, the system will give out warning in case of beyond the range.
Hereby, it is to omit the test by pressing DELETE. At end of each test, if the printer is
preset to ON, the data will be printed out automatically.
6) Turn the elevating handle to let the screw rod descend so as to remove the preliminary
test force. Then the light band will disappear, which means the end of one test cycle.
The hardness value will be remained until the start of next test.
NOTE:
During the operation of step 5 and step 6, load changeover handle shall not be turned
to prevent from damaging the tester.
The first test after anyone of indenter, specimen or the anvil is changed shall be
regarded invalid.
IV. Maintenance
1. Cleaning and Lubrication
l Cover the tester in case of no use for a long time.l Fill with adequate machine oil into the contacts between screw rod and handle
regularly.
2. Calibration
Examine the accuracy of the tester with the standard hardness block delivered with
the tester.
l The tester should be calibrated regularly. The interval of calibration shall be less than12 months.
l Clean the anvil and standard hardness block. The test shall be carried out on theproper testing surface. It is not allowed to make test on the supporting surface.
l If the reading error is beyond expectation, besides the regular examination listed inTable 7, the support surface shall be inspected and remove the burrs if any with oil
stone.
l The hardness block shall be moved along the worktable rather than fetch it from oneplace to another.
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V. Hardness Value Correction
Since the measured value is reduced for convex specimen, the correction shall be
added. While for concave specimen, the correction shall be reduced. The correction to
other diameters or hardness values could be obtained by method of insertion.
Table 5 Correction for C and A scales of Cylindrical specimen
Diameter of cylindrical specimen (mm)
6.4 10 13 16 19 22 25 32 38
Specimen
HardnessCorrection
20 6.0 4.5 3.5 2.5 2.0 1.5 1.5 1.0 1.0
25 5.5 4.0 3.0 2.5 2.0 1.5 1.0 1.0 1.0
30 5.0 3.5 2.5 2.0 1.5 1.5 1.0 1.0 0.5
35 4.0 3.0 2.0 1.5 1.5 1.0 1.0 0.5 0.5
40 3.5 2.5 2.0 1.5 1.0 1.0 1.0 0.5 0.5
45 3.0 2.0 1.5 1.0 1.0 1.0 0.5 0.5 0.5
50 2.5 2.0 1.5 1.0 1.0 0.5 0.5 0.5 0.5
55 2.0 1.5 1.0 1.0 0.5 0.5 0.5 0.5 0
60 1.5 1.0 1.0 0.5 0.5 0.5 0.5 0 0
65 1.5 1.0 1.0 0.5 0.5 0.5 0.5 0 0
70 1.0 0.5 0.5 0.5 0.5 0.5 0.5 0 0
75 1.0 0.5 0.5 0.5 0.5 0.5 0 0 0
80 0.5 0.5 0.5 0.5 0.5 0 0 0 0
85 0.5 0.5 0.5 0 0 0 0 0 0
90 0.5 0 0 0 0 0 0 0 0
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Table 6 Correction for B scale of Cylindrical specimen
Diameter of cylindrical specimen (mm)
6.4 10 13 16 19 22 25
Specimen
HardnessCorrection
0 12.5 8.5 6.5 5.5 4.5 3.5 3.0
10 12.0 8.0 6.0 5.0 4.0 3.5 3.0
20 11.0 7.5 5.5 4.5 4.0 3.5 3.0
30 10.0 6.5 5.0 4.5 3.5 3.0 2.5
40 9.0 6.0 4.5 4.0 3.0 2.5 2.5
50 8.0 5.5 4.0 3.5 3.0 2.5 2.0
60 7.0 5.0 3.5 3.0 2.5 2.0 2.0
70 6.0 4.0 3.0 2.5 2.0 2.0 1.5
80 5.0 3.5 2.5 2.0 1.5 1.5 1.5
90 4.0 3.0 2.0 1.5 1.5 1.5 1.0
100 3.5 2.5 1.5 1.5 0 1.0 0.5
VI. Troubleshooting
In case of breakdown, the following may be of help to predict the breakdown and
recommend the methods of troubleshooting. If remains unsolved, please contact our
after-sales service department instead of dismantling the tester by yourself.
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Table 7 Guidance to troubleshooting
Troubles Reasons Method of troubleshooting
Lag of screw rod Rusty or chips Get rid of chips and fill with lubricants
Main test force
failed to apply
Weights not hanged
properlyAdjust the position of weight group
Test forceWhether the preset test forces conform to
the requirements of the selected scale
Distance of
indentations
Distance between the centers of two
adjacent indentations is not big enough.Whether the indenter conforms to the
requirements of the selected scale
Eliminate the space between indenter and
main shaft
Indenter
Replace the indenter if damaged
Examine whether there are impurities
between test anvil and indenterWhether or not the test anvil is suitable for
the specimenTest anvil
Examine whether the protective sleeve
props up the test anvil
Examine whether the test force is
perpendicular to the surface
Remove any burrs on the back of
specimen
Specimen
Thickness of specimen is too small
Mechanical vibration nearlySurroundings
Ambient temperature beyond 10-30C
Measured
hardness value
not precise
Others Calibrate with standard block