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1.
International Research Journal
of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 06 Issue: 03 | Mar 2019 www.irjet.net p-ISSN: 2395-0072 © 2019, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 3066 ROCKWELL BASED HARDNESS TESTING MACHINE Bhagyashri Sakat1, Sujata Sonavane2, Foujiya Shaikh3,Prof. Pradnya Narvekar4 1,2,3Student Department of Elecronics and Telecommunication Engineering, Sanjay Ghodawat Collage of Egineering, Atigre, Kolhapur 4Assistant Professor Department of Elecronics and Telecommunication Engineering, Sanjay Ghodawat Collage of Egineering, Atigre, Kolhapur ---------------------------------------------------------------------***---------------------------------------------------------------------- Abstract – The measurement of hardness is widely used by many of the world’s manufacturing industries. The hardness tests are the most commonly used methods for testing and production quality-control of metals and metallic products. This paper represents that hardness testing machine using digital system. Where semi-automatic motorized digital machine, raspberry pi based panel is used. We can get hardness in digital version, where parallel port for connecting dot matrix printer is also used. This machine operates in three modes motorized automatic mode, motorized mode & manual mode. In this project automatic weight selection by thumb wheel is provided. 1. INTRODUCTION P. Rockwell invented the Rockwell hardness test to get more accurate and rapid measurement. After that Charles H. Wilson expanded on Rockwell’s invention. The Rockwell is a hardness scale based on indentation hardness of material. The Rockwell hardness test based upon Measurement of depth to which an indenter is forced by major loadbeyondthedepthresultingfrom a previous load(minor) load. The principle of working is firstly minor is applied. A zero position is recorded. After that major load is applied and the maximum penetration position is recorded. After that remove the major load until minor load is reached. Resulting Rockwell no. displayed. It is difference between major load and minor load. The indenter may be either a diamond cone &tungsten carbide ball, depending upon the characteristics of the material being tested. In this project paper, this machine is designed for measuring hardness of metals & alloys, whether round, flat or irregular in shapes. This machineis ideally suitable for laboratories, tool rooms, heat treatments shops, R&D departments, inspection departments, foundries& educational institutions. Automatic weight selection with automatic zero setting dial guage. Motorized versions are also available. 2. BLOCK DIAGRAM HMI: Key Words: indenter, penetrate, hardness, raspberry
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International Research Journal
of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 06 Issue: 03 | Mar 2019 www.irjet.net p-ISSN: 2395-0072 © 2019, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 3067 A human-machine interface (HMI) is the user interface which connects the system and user to control the system.MItranslate the system data into the human-readable visual representation of the system. It used to connect human to machine. With the help of HMI easy to understand graphics display. Functions for converting values and compensating for curved surface. Raspberry pi: Raspberry pi is easy to use as compared to the other models. It has 1GB DDR3 RAM which helpful in Rockwell based hardness testing machine because it requires more space to store information or calculations. In this project we can use raspberry pi3 model B+ .it includes a GB wired LAN adapter, different 802.11n WIFI cards. Driver module: When we working with electronics project which used microcontroller/raspberry pi, it requires relay to control ACvoltageor high voltage and this driver module provide isolation between raspberry pi circuit and highvoltageoperatingloads.itincludes optocoupler,ULN2003 and relay etc. Wiper motor: In this project wiper motor 17w 24 v is used. Designed for wind shield wiping on light commercial and commercial vehicles. Linear encoder : Linear encoder is traducer or sensor which convert encoded position into analog or digital form. Here it will detect positionof minor load and major load and convert it into digital output.
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International Research Journal
of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 06 Issue: 03 | Mar 2019 www.irjet.net p-ISSN: 2395-0072 © 2019, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 3068 3. FLOW DIAGRAM: Different types of parameters of test can set on setting screenontouchscreen.In normal mode,preload(minorload)is applied. And zero data is recorded after that a major load is applied for specific time of period because of that penetration depth beyond the zero data which is previously established by the minor load. After that the specified dwell time for major load, the major load is removed by keeping Minor load. This loading and unloading reading taken by the encoder. This data sends to the HMI. The difference between minor load and major load which is Rockwell hardness number displayed on HMI screen. 4. TABLES, FIGURES AND EQUATIONS 4.1 Tables: 1. In this project paper different scales are used to measure hardness, depends on scale different metals are used as shown as follows: Scale symbol Typical applications A Cemented carbides, thin steel & shallow case- hardened steel B Copper alloy, soft steel aluminum alloys , etc. C Steel , hard cast iron , titanium and other materials harder than B100 D Thin steel and medium case- hardened steel. E Cast iron, aluminum & magnesium alloys, bearing metals G Phosphor bronze, beryllium copper, malleable irons, F Annealed copper alloys, thin soft sheet metals H Aluminum, zinc lead 2. For different scales, different indenter are used which is depend on load. Which is as shown in table as below: Scale symbol indenter Load (kgf) A Diamond 60 B 1/16*Ball 100 C Diamond 150
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International Research Journal
of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 06 Issue: 03 | Mar 2019 www.irjet.net p-ISSN: 2395-0072 © 2019, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 3069 D Diamond 100 E 1/8*Ball 100 F 1/16*Ball 60 G 1/16*Ball 150 H 1/8*Ball 60 K 1/8*Ball 150 L 1/4*Ball 60 M 1/4*Ball 100 P 1/4*Ball 150 R 1/2*Ball 60 S 1/2*Ball 100 5. Equations The formula used for the calculating Rockwell hardness values are as follows: 1. For regular Rockwell hardness using spheroconical “brale” indenter HR[scale] = 100 – h/0.002 Where scales is A, B,C,D & depth penetrated in mm. 2.Using steel ball: HR[scale]= 130 – h/0.002 Where scales is B, E, F, G etc. and h in mm. 3. for superficial Rockwell hardness usingindenter. HR=[(total load ) scale] = 100 – h/0.001 Where total load is 15, 30, or 45kgH in mm. 6. DEMO PROJECT: CONCLUSION In normal Rockwell based hardness testing machine itoperatedmanually,thetestforceselectionisdone bymanually.Indigital Rockwell based hardness testing machine, It is motorized testing machine which provides automatic operations cycle. It includes load, dwell and unload operations. Or externally dialing is done by LCD display.
5.
International Research Journal
of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 06 Issue: 03 | Mar 2019 www.irjet.net p-ISSN: 2395-0072 © 2019, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 3070 REFERENCES [1] ISO 6508-3 Metallic Materials – Rockwell hardness test (scales A, B, C,D, E, F, G, H, K, N, T) – Part 3: Calibration of reference blocks, Geneva, International Organization for Standardization, 1999. [2] ASTM E 18 – 2000, Standard Test Methods for Rockwell Hardness and Metallic Materials, West Conshohocken, PA, ASTM, 2000.
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