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).

Rockwell hardness value = Nh/S Table 1 Symbols and Descriptions Symbols F0 F1 F S N h HRA HRC HRB Main test force Total test force Unit of given scale Hardness value of given scale Residual indentation depth under preliminary test force after main test force is removed Rockwell hardness = 100h/0.002 Rockwell hardness = 130h/0.002 Descriptions Preliminary test force

Formula (1)

Units N N N mm

mm

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 standard Metallic 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
2

range of measurement is 2085HRA. l Scale B is used to measure the lower-hardness parts whose range of hardness shall be 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, such as 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 Table 2 Usual scales for Rockwell Hardness

Fig-3 Steel ball indenter

Scale A B C

Indenter (mm) Diamond cone indenter Steel ball indenter (1.588mm) Diamond cone indenter

Test force (kgf) F0 10 10 F1 50 90 F 60 100

Constant N 100 130 100

Application examples Hard metal and alloy Non-ferrous and soft metal Structural and tool steel

10 140 150

4. Technical Parameters Please refer to Table 3 and Fig-4 for main technical parameters. Table 3 Main Technical Parameters Itemcode HeightH WidthW LengthL Maximum height of specimen (with sleeve)B Maximum height of specimen (without sleeve)B Depth of throat (A) Net weight Power supply Content 729mm 225mm 522mm 140mm 210mm 165mm 98Kg 110 / 220V, 50Hz

Reference Scales

Range of Harness

Reading Allowance

20HRA~75 HRA A >75HRA~88 HRA 20HRB~45HRB B >45HRB~80HRB >80HRB~100 HRB C 20HRC~70HRC

2 HRA 1.5 HRA 4HRB 3HRB 2 HRB 1.5HRC

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 other components directly or indirectly. Except the worktable (5), screw rod (4) and elevating 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. The preliminary 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 sharp end is pressed into the surface of the specimen. l To select different weights and combine them in different group to obtain required
5

total test forces including 588N/60Kgf, 980N/100Kgf and 1470N/150Kgf, l Loading and unloading mechanism is composed of motor and roller wheel. The motor 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 wheel 4. 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 handle 27. Indenter
6

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 Operation Manual, 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 box and verify whether all the parts contained in the packing list are available.
7

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 or personal 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
8

rod should not be over 15 against the vertical line. l During the transportation, the contacts between the operators and the tester are limited to 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 falls through 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 and rear 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.

Fig-9 Removing the binding rope 6) Turn the elevating handle anticlockwise to let the screw rod coming downwards, and then 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

10

7) Remove the protective sleeve, clean the antirust grease on the screw rod and elevating screw 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 the levelness 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 l To be well versed with the functions of front and rear panel. Front Panel

Fig-11 Schematic Diagram of Front Panel 1) RESET: resume to initial status 2) CLEAR: to zero the displacement value
11

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 to return. 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 pressing UP or DOWN arrow key. Then press OK for confirmation or ESC to return.
12

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 shown in Fig-12.

Fig-12 Schematic Diagram of Rear Panel l Other preparations 1) 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)

13

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 of centers 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.

14

Table 4 Minimum Thickness Scales Hardness HR 70 A 80 90 25 30 B 40 50 60 70 Min. thickness mm 0.7 0.5 0.4 2.0 1.9 1.7 1.5 1.3 1.2 C B Scales Hardness HR 80 90 100 20 30 40 50 60 70 Min. Thickness mm 1.0 0.8 0.7 1.5 1.3 1.2 1.0 0.8 0.7

b. The surface to be tested should be flat plane. In case of curved plane, the test results 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 shall be 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 perpendicular to 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.

15

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 (see Fig-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
16

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 the indenter 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.
17

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 than 12 months. l Clean the anvil and standard hardness block. The test shall be carried out on the proper 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 in Table 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 one place to another.
18

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 Specimen 6.4 Hardness 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 6.0 5.5 5.0 4.0 3.5 3.0 2.5 2.0 1.5 1.5 1.0 1.0 0.5 0.5 0.5 4.5 4.0 3.5 3.0 2.5 2.0 2.0 1.5 1.0 1.0 0.5 0.5 0.5 0.5 0 3.5 3.0 2.5 2.0 2.0 1.5 1.5 1.0 1.0 1.0 0.5 0.5 0.5 0.5 0 2.5 2.5 2.0 1.5 1.5 1.0 1.0 1.0 0.5 0.5 0.5 0.5 0.5 0 0 10 Diameter of cylindrical specimen (mm) 13 16 19 Correction 2.0 2.0 1.5 1.5 1.0 1.0 1.0 0.5 0.5 0.5 0.5 0.5 0.5 0 0 1.5 1.5 1.5 1.0 1.0 1.0 0.5 0.5 0.5 0.5 0.5 0.5 0 0 0 1.5 1.0 1.0 1.0 1.0 0.5 0.5 0.5 0.5 0.5 0.5 0 0 0 0 1.0 1.0 1.0 0.5 0.5 0.5 0.5 0.5 0 0 0 0 0 0 0 1.0 1.0 0.5 0.5 0.5 0.5 0.5 0 0 0 0 0 0 0 0 22 25 32 38

19

Table 6 Correction for B scale of Cylindrical specimen Specimen Hardness 0 10 20 30 40 50 60 70 80 90 100 6.4

Diameter of cylindrical specimen (mm) 10 13 16 Correction 12.5 12.0 11.0 10.0 9.0 8.0 7.0 6.0 5.0 4.0 3.5 8.5 8.0 7.5 6.5 6.0 5.5 5.0 4.0 3.5 3.0 2.5 6.5 6.0 5.5 5.0 4.5 4.0 3.5 3.0 2.5 2.0 1.5 5.5 5.0 4.5 4.5 4.0 3.5 3.0 2.5 2.0 1.5 1.5 4.5 4.0 4.0 3.5 3.0 3.0 2.5 2.0 1.5 1.5 0 3.5 3.5 3.5 3.0 2.5 2.5 2.0 2.0 1.5 1.5 1.0 3.0 3.0 3.0 2.5 2.5 2.0 2.0 1.5 1.5 1.0 0.5 19 22 25

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.

20

Table 7 Guidance to troubleshooting Troubles Reasons Method of troubleshooting Get rid of chips and fill with lubricants

Lag of screw rod Rusty or chips

Main test force Weights not hanged Adjust the position of weight group failed to apply properly Test force Distance indentations Whether the preset test forces conform to the requirements of the selected scale of Distance between the centers of two adjacent indentations is not big enough. Whether the indenter conforms to the requirements of the selected scale Indenter Eliminate the space between indenter and main shaft Replace the indenter if damaged Examine whether there are impurities between test anvil and indenter Whether or not the test anvil is suitable for the specimen Examine whether the protective sleeve props up the test anvil Examine whether the test force is perpendicular to the surface Specimen Remove any burrs on the back of specimen Thickness of specimen is too small Surroundings Others Mechanical vibration nearly Ambient temperature beyond 10-30C Calibrate with standard block

Measured hardness value Test anvil not precise

21