1.

Support structure and chassis

Sizing steps:

 Definition of loads and stresses: Identify all the static and dynamic loads that the bench will
have to support (weight of the devices, load application forces, vibrations induced by the
operation of the mechanism, etc.). For example, you can estimate the maximum loads
generated when applying a hardness test, as well as the reaction forces on the bench.

 Choice of materials and sections: The document indicates a steel or anodized aluminum
construction. For each structural component, select the material based on its mechanical
properties (modulus of elasticity, yield strength, density). Use formulas from the strength of
materials (such as bending, σ = M⁄W, where M is the bending moment and W is the modular
section) to determine the minimum thickness and dimensions to avoid excessive deformation
or deflection.

 Finite Element Analysis (FEA): For complex shapes (fasteners, gantry-type assemblies), it is
recommended to use finite element analysis software to evaluate the stress distribution and
identify critical areas. This makes it possible to validate the choice of cross-sections and to
refine the dimensions taking into account the stress concentrations.

 Application of a safety factor: Integrate a safety factor (often between 1.5 and 2, or even
more, depending on use and risks) to cover unforeseen events (material variability, accidental
overloading, fatigue).

2. Load application mechanism

Sizing steps:

 Determination of the force to be applied: Calculate the maximum expected force to be

applied to the specimen during the hardness test. This includes the study of progressive
unloading (to go from elastic to plastic regime).

 Selection of the mode of action (manual vs. motorized/hydraulic): In a manual version, the
main element is often a crank. The sizing will then involve the calculation of the lever arm
and the necessary force moment:

M=F×lM = F \times l

where il is the effective length of the crank. For a motorized or hydraulic version, it will be necessary
to analyze the capacity of the cylinder (force, stroke, speed) and check that its torque or power is
adequate to reach the required load.

 Calculation of mechanical stresses on the mechanism: Check the rigor in the connection
points and bearings. Use stress diagrams to ensure that parts (gears, bearings, shafts) do not
exceed their limits of use. Properties such as wear resistance and fatigue must be considered.

3. Indenter/Fingerprint

Methodology and criteria:

 Choice of geometry and material: The indenter must have a precise shape (spherical for a
Brinell test, conical/pyramidal for other methods) and be made of a material that is much
harder than the materials being tested (e.g., hardened steel or diamond). For sizing, you
must:
 o Determine the required diameter or angles to ensure a repeatable and standards-
compliant footprint.

o Ensure that dimensional tolerances are very tight to avoid variation in the hardness
calculation.

 Calculation of the cavity and verification of hardness formulas: In the case of the Brinell
test, the formula used relates the force applied, the diameter of the ball and the indentation
left. The indenter is therefore dimensioned by validating that, for the maximum force applied,
the deformation produced is within the optimal measuring range and that the tool does not
undergo any plastic deformation in turn.

4. Load Measuring Device

Sizing approach:

 Load Cell Selection: The first step is to determine the measurement range (the maximum
expected load) and resolution needed to obtain accurate data. You can use load cells or
digital dynamometers. For example, size the sensor so that:

o The output remains linear with respect to the applied force.

o The sensitivity and precision (resolution typically on the order of a few Newtons or
less, depending on the context) are sufficient for the tests envisaged.

 Signal calibration and conversion: The analog signal produced by the sensor is then
converted by an ADC. The ADC (number of bits) must be sized and filtering circuits must be
set up to eliminate noise. Calibration tests using calibrated masses or forces will validate the
linearity and accuracy of the device.

5. Indentation Measuring Device

Techniques and sizing:

 Choice of measurement method: The device can be optical (microscope, digital comparator)
or mechanical. The choice depends on the desired resolution (often up to 0.01 mm). It must
be ensured that the method chosen provides sufficient accuracy to measure the exact size of
the indentation, which is essential for the calculation of the hardness index.

 Sizing the optical or mechanical calibration: Size the device so that the conversion (e.g.,
pixels to millimeters) is done accurately. This may involve:

o The use of dimensional standards (standard ruler, micropapers) for calibration.

o The choice of an imaging system with a field of view adapted to the size of the
impressions generated.

6. Data acquisition system and user interface

Configuration and sizing:

 Electronic System Specifications: Size the acquisition system based on the sampling rate
required to capture the dynamics of load and strain. For example, for rapid signal variations, a
high rate is required (sometimes several kilohertz).
  Analog-to-Digital Conversion (ADC): Choose an ADC with sufficient resolution (e.g., 16-bit) so
that quantization does not limit the accuracy of the measurement. The sizing must also take
into account the channels (for several simultaneous sensors) and the bandwidth.

 User interface and processing software: The interface should be designed to process and
display data from sensors in real time. The software must allow a graphical visualization
(Force/Time, Deformation/Time curves, etc.) as well as a statistical analysis. The robustness
and speed of calculation influence the choice of computer hardware and processing
algorithms.

7. Accessories and Sample Holders

Key points for sizing:

 Design of Fasteners: These brackets must secure the specimen in a manner that prevents
slippage or vibration that could bias the measurements. The sizing is based on:

o The calculation of the clamping forces required to counter the applied load, taking
into account the coefficient of friction between the support and the specimen.

o The selection of robust and precise materials, capable of maintaining their

dimensional integrity under repeated testing.

 Adaptability to different shapes: Make sure that the supports can accommodate various
samples (shapes, dimensions). This sometimes involves a modular design with adapters
whose rigidity and stability must be verified by simple calculations when mechanical
connections (bolts, screws) are involved.

8. Security Systems

Sizing and criteria:

 Emergency stop and interlock devices: These systems must be designed to immediately stop
the test in the event of an anomaly. Their sizing will include:

o Calculation of the maximum forces that can be stopped by the safety mechanism
without damaging the device.

o The selection of robust and reliable components (buttons, barriers, locks) with a high
security factor, often calculated on industrial standards (ex. ISO, NF).

 Robustness and responsiveness: Verify that control circuits and sensor monitoring software
respond in a very short time to ensure operator and device protection. Extreme stress tests
(overload tests) are used to validate the behaviour of the safety systems.

General integration and recommendations

1. Identification of functional and normative requirements: – Identify the conditions of use,

the maximum load and the precision requirements. – Consider the safety standards and
recommendations in mechanical engineering.

2. Application of the classic material strength formulas: – For each load-bearing component
(frame, beams, supports), apply the formulas for bending, shear and compression. – For
example, for a bending element, determine the maximum bending moment, calculate the
 required resistance section and compare with the available cross-section by adding a safety
factor.

3. Use of simulation software: – Before manufacturing, finite element analysis (FEA) provides a
precise view of the stresses and optimizes the geometry of the components.

4. Calibration and quality control: – For measuring devices (force sensors, impression
measurement), provide calibration phases using known standards to ensure data reliability.

5. Documentation and iteration: – Keep full traceability of the design (calculations,

assumptions, experimental tests) and iterate if anomalies or inaccuracies are detected during
the tests.

In summary, the sizing of the components of a didactic bench for the hardness testing of materials
involves an integrated approach combining the mechanics of continuous media, precision electronics
and a rigorous study of safety. This approach guides you from load estimation and material selection
to validation by simulation and experimental calibration. Every element, whether it is the chassis, the
load application mechanism, the indenter, the measuring devices or the safety systems, must be
dimensioned in such a way as to ensure maximum stability, reproducibility and accuracy for the entire
system.

1. Inventory of the Didactic Bench for the Hardness

Testing of Materials
Component Quantity required Feedback

The complete assembly (structural core) made of anodized

Support structure and
1 steel or aluminum, ensuring the rigidity and stability of the
chassis
device.

Load application Loading system (manual by crank or motorized/hydraulic)

1
mechanism allowing the gradual application of force on the specimen.

For example, a ball for the Brinell test or a diamond tool

Indenteur / Empreinte 1 for Vickers – the tool must be unique and meet tight
tolerances.

Includes the sensor(s) (load cells or dynamometer) to

Load Measuring
1 set convert the applied force into an electrical signal, with
Device
built-in calibration.

Measuring system (optical microscope, digital comparator

Indentation
1 set or optical reading device) capable of measuring with an
Measuring Device
accuracy of close to 0.01 mm.

Integrates electronic hardware (ADC, acquirer card) and

Data acquisition 1 complete
data display/processing software to visualize curves in real
system and interface system
time.
Component Quantity required Feedback

Sample Accessories & Includes all the devices (clamps, holders, guides) that
1 complete kit
Holders allow samples of different shapes and sizes to be fixed.

Includes emergency stop devices (stop button, gates,

Security systems 1 set locks). The whole must comply with the safety standards in
force.

Sensor or dynamometer connected to the cylinder,

Built-in force sensor 1
measuring the force applied with good resolution.

Measures the displacement of the cylinder, which is

Displacement sensor 1 essential to monitor the progress of the test and feed the
data acquisition system.

Embedding (sample
1 Fixed holder to lock the sample during the test.
holder)

Movable crossbar
1 Allows adjustment of the test area with pin locking.
with adjustable height

For actuation control. Note: A "2 cylinders" option is

Electric actuator (1 1 (Standard
available if you want to double the actuator for certain
kN) Configuration)
applications.

Groups electrical protection devices and ensures standard-

Electrical control box 1
compliant control.

Control box / PC Allows communication between the bench and the

1
interface computer for piloting via the X software.

Inventory of the Electrical Control Box

Quantity
Component Feedback
Required

Insulating metal casing intended to house all the

1. Electrical Cabinet/Box 1 components. Must meet IP standards (e.g. IP54 or higher
depending on the operating environment).

Overall circuit protection against overload and short

2. Main Circuit Breaker 1 circuit – sized in accordance with the total power of the
system (e.g. 16A or 20A for a 230V power supply).

3. Master Switch/Disconnect 1 Allows the power supply to be cut off to the entire
Switch enclosure for maintenance or in case of emergency,
 Quantity
Component Feedback
Required

guaranteeing the safety of the installation.

Used to control and isolate actuator circuits (e.g. the

4. Contactors and Control
2 electric actuator). The precise number may vary
Relays
depending on the complexity of the piloting.

Provides real-time control and servo control. This central

5. Programmable Logic
1 module controls all input/output signals and executes
Controller (PLC)
the control program.

Allows the connection of sensors and actuators (force,

6. I/O Modules 1 set displacement, etc.). They ensure the conversion of
signals and their transmission to the PLC.

Converts mains voltage (230V) into stable voltages

7. Electronic Power Supply
1 suitable for logic circuits and control modules (often 24V
(PSU)
DC for industrial control).

Used to organize and secure internal wiring, facilitate

8. Terminal Blocks 1 set circuit distribution and allow subsequent connection of
input and output cables.

Additional protection for various sensitive internal

9. Personal Fuses/Protective
2 to 3 sets circuits. Each branch (e.g. PLC or power contacts) must
Devices
be protected by a suitable fuse.

Device(s) essential to allow immediate de-energization in

10. Emergency Stop Button(s) 1 or 2 the event of an anomaly. Often positioned on top or in
the immediate vicinity of the box.

Provide a visual indication of system status (power,

11. Indicator lights /
3 to 4 operation, fault); facilitate quick diagnosis in the event of
indicators (LEDs)
a problem.

Includes power cables, signal cables, cable ties,

12. Miscellaneous Wiring,
(Overall) protective jackets, and other accessories necessary for a
Connectors and Accessories
neat and compliant installation.

Load Application Mechanism Inventory

Quantity
Component Feedback
required

1. Actuator (electric 1 Allows the conversion of a control to mechanical force. In a

actuator or crank) didactic context, the electric actuator (capable of
 Quantity
Component Feedback
required

approximately 1 kN) is commonly used.

Including rails or slides and connecting arms/adapters. They

2. Guidance and
2 sets ensure linear and precise movement of the actuator, limiting
transmission system
lateral movement.

Fasteners that ensure load distribution and mechanism

3. Connecting arms and
2 stability while ensuring proper alignment between actuator
brackets
and indenter.

Allows the speed and rate of load application to be

4. Control module and
1 controlled in real time, often integrated via dedicated
servo control
software (e.g., via the Quant X system).

Measures the force actually applied by the cylinder,

5. Force sensor (load cell) 1 providing much-needed feedback to adjust the load
application.

Monitors the actuator stroke and verifies that the movement

6. Displacement sensor 1
is gradual and controlled.

Ensures system safety, allowing immediate interruption of

7. Emergency stop button 1 the charging application in the event of an anomaly or
malfunction.

Includes all the power and signal cables, jackets, and

8. Wiring, connectors and
Together connections needed to connect all subsystems reliably and
protective accessories
compliantly.

Protects the electrical circuit from overloads and short

9. Fuses and Personal
1 set circuits, ensuring the durability and safety of the mechanism
Protection Devices
during testing.

An indenter is used to measure the hardness of a material. The indenter can measure different types
of hardness: vickers hardness, Brinelle hardness, Knoop hardness, Janka hardness and Rockwell
hardness. The indenter allows a specific load to be applied to the surface of the material (in the same
way as an indenter).