Experiment -3

Aim: To study the Rockwell hardness testing machine &perform the Rockwell hardness test.
Requirements: Rockwell hardness testing machine, testing specimen
Theory: Hardness is a characteristic of a material, not a fundamental physical property. It is
defined as the resistance to indentation, and it is determined by measuring the permanent depth
of the indentation. More simply put, when using a fixed force (load) and a given indenter, the
smaller the indentation, the harder the material. Indentation hardness value is obtained by
measuring the depth or the area of the indentation using one of over 12 different test methods.
The Rockwell hardness test method, as defined in ASTM E-18, is the most commonly used
hardness test method. The Rockwell test is generally easier to perform, and more accurate
than other types of hardness testing methods.The Rockwell test method is used on all metals,
except in condition where the test metal structure or surface conditions would introduce too
much variations; where the indentations would be too large for the application; or where the
sample size or sample shape prohibits its use. The Rockwell method measures the permanent
depth of indentation produced by a force/load on an indenter. First, a preliminary test force
(commonly referred to as preload or minor load) is applied to a sample using a diamond or ball
indenter. This preload breaks through the surface to reduce the effects of surface finish.
After holding the preliminary test force for a specified dwell time, the baseline depth of
indentation is measured. After the preload, an additional load, call the major load, is added to
reach the totalrequired test load. This force is held for a predetermined amount of time (dwell
time) to allow for elastic recovery. This major load is then released, returning to the preliminary
load. After holding the preliminary test force for a specified dwell time, the final depth of
indentation is measured. The Rockwell hardness value is derived from the difference in the
baseline and final depth measurements. This distance is converted to a hardness number. The
preliminary test force is removed and the indenter is removed from the test specimen.
The schematic diagram of the testing machine is shown in fig. 1.
Front Cover Upper Cover

key Pane!

Ipdenter Fastening
Serew
Liftüng Rod

load acusting wlheel

Switch
Test Stage

|Power Cable
Rotary IWheel

Fuse

Fig, 1Testing machine

Preliminary test loads (preloads) range from 3 kgf (used in the "Superficial" Rockwell scale)
to 10 kgf (used in the "Regular" Rockwell scale).Total test forces range from 15kgfto 150 kgf
(superficial and regular) to 500 to3000 kgf (macro-hardness), as shown in fig. 3.
Test Method Illustration

The process of the test is illustrated in fig. 2, where,

A=Depth reached by indenter after application ofpreload (minor load)
B= Position of indenter during Total load, Minor plus Major loads
C= Final position reached by indenter afier elastic recovery of sample material
D =Distance measurement taken representing difference between preload and major load
position. This distance is used to calculate the Rockwell Hardness Number.

A B

Minor Load Minor Load Minor Load

plus Major Load =Total Load

Zero Relerence line

Fig. 2 Process of testing

Avariety of indenters may be used: conical diamond with around tip for harder metals to ball
indenter's ranges with a diameter ranging from 1/16° to 1/2" for softer materials.
When selecting a Rockwell scale, a general guide, shown in fig. 3, is used to select the scale
that specifies the largest load and the largest indenter possible without exceeding defined
operation conditions and accounting for conditions that may influence the test result. These
conditions include test specimens that are below the minimum thickness for the depth of
indentation; a test impression that falls too close to the edge of the specimen or another
impression; or testing on cylindrical specimens.
Additionally, the test axis should be within 2-degress of perpendicular to ensure precise
loading; there should be no deflection of the test sample or tester during the loading application
from conditions such as dirt under the test specimen or on the elevating screw. It is
important
to keep the surface finish clean and decarburization from heat treatment should be removed.
Sheet metal can be too thin and too soft for testing on a particular Rockwell scale without
exceeding minimum thickness requirements and potentially indenting the test anvil. In this case
a diamond anvil can be used to provide a consistent
influence of the result.
 ROCKWELL HARDNESS SCALES
treiminary
Indentet bpe tetalEorce Iypical Appfieatlens
Smbol Force
(emento carbds, thin feci, and haflos cAe
Snheresonical Daod 8S 4 (60)
hardened stee
(osoer alkoy f steek alumn,n alloys
Ral!
aile ae iros, cK
`ret. hard sat irors, pearfitc salleahle iron
(471(e0)tatiurn, deep cac hsrdencd steel. and otber
Sphenshical DaOd
ma'nalk hrder th HRB I00
Tin siee! ant meun case hardend tteel, snal
Snherroscal farnd 98 07 (0)
CAt Hon, siumunum an gtsiut1 alloy, and
9807()
98 07(1) $8S 4 {) Arnealed cngper allovs, aÞ thin soft cheet metals
Malleahe iron, copper nkel inc and cupro
1471(1SO) skel aly
$88 4 ( )
Alumiunt, in, nd ie
9% 97(0)
14310)

Bal! 6.iS0 ! 4 is 98 07(10)

GAO7(1t*)ernt mxetals snd other sery soft or then cnateials

14 o) Ue snallest all a eavicst load that does not
1gise aris il efect

Bali- 1?0m )807(O

14241SN

ShetoonKa) )hamwal 29.42 (3) |47 ||S)

Srnslet to A C and D sales, but for thinner gage
294211 ntetialor cuse desh
Spherunnal arToo 294213) 441 1(45)

2942 42.J03} Star o Hard r caes, Put for thinne RAe

:942() 2942D)
2942(3)

9,403 44)345
2242) 147 11S)

Hall - 3S0 mn ( 4 n 294243) 294244) Very seth mateal

45X 29 42 (3) 441 3(45)

Rall 12.70 mm (U2 in 2942 (3)
Hall 12.70tmm(1/2 n.) 29423) 294230)

45Y Ball- 12,70 mu(l/2 n 2442 13) 4413 (45)

Fig. 3Rockwell hardness scale

Another special case in testing cold rolled sheet metal is that work hardening can create a
gradient of hardness through the sample so any test is measuring the average of the hardness
over the depth of indentation effect. In this case any Rockwell test result is going to be subject
to doubt, there is often a history of testing using a particular scale on a particular material that
operators are used to and able to functionally interpret.
Test Procedure:

i Connect the power supply cable and switch on. Current test parameters, which are
stored automatically before last shutting off, will be displayed.
i. Select the scale and the indenter according to the application and material of the
specimen.
ii. Setthe selected scale in the machine at the display unit.
iv. Set the definedweight byrotating the side wheel.
Place the sample to be tested on the anvil.
Vi. Smoothly rotate the hand wheel in clockwise touplift the anvil untilthe sample has
beencontacted with indenter.
vii. Rotate the hand wheel slowly and smoothly until the cursor in the figure reaches
the end position.
 DDDDDDDD
viii.
Buzzing warning will be given out at the same time and the rotating should be
stopped at once.
iX. Loading of the main load and hold it till the machine gives beep sound.
X.
Unload the specimen by moving the lever back to its initial position.
Xi. Data processing will take place and the result will be displayed on the screen as
hardness value.
Observations:

i. Material of the test piece =

ii. Thickness of test piece =
iii. Hardness scale used =
iv. Minor load =
V. Major load =
Hardness 1 Hardness 2 Hardness 3 Average Hardness
(HR-scale)

Results:

The Rockwell hardnessof the tested spe