Exp. No.

1
(a) Rockwell Hardness Testing

Introduction

This hardness test uses a direct reading instrument based on the principle of differential
depth measurement. Rockwell testing differs from Brinell testing in that the Rockwell hardness
number is based on an inverse relationship to the measurement of the additional depth to which
an indenter is forced by a heavy (major) load beyond the depth resulting from a previously
applied (minor) load. Initially a minor load is applied, and a zero datum position is established.
The major load is then applied for a specified period and removed, leaving the minor load
applied. The resulting Rockwell number represents the difference in depth from zero datum
position as a result of the application of major load. The entire procedure requires only 5 to 10 s.
Use of a minor load greatly increases the accuracy of this type of test, because it eliminates the
effects of backlash in the measuring system and causes the indenter to break through slight
surface roughness.
The 120 sphero-conical diamond indenter is used mainly for testing hard materials such
as hardened steels and cemented carbides. Hardened steel ball indenters with diameters 1/16, 1/8,
1/4, 1/2 in. are used for testing softer materials such as fully annealed steels, softer grades of cast
irons, and a wide variety of nonferrous metals.
In Rockwell testing, the minor load is 10 kgf, and the major load is 60, 100 or 150 kgf. In
superficial Rockwell testing, the minor load is 3 kgf, and major loads are 15, 30 or 45 kgf. In
both the tests, the indenter may be either a diamond cone or steel ball, depending principally on
the characteristics of the material being tested.
There are 30 different Rockwell scales, defined by the combination of the indenter and
minor and major loads. The suitable scale is determined due to the type of the material to be
tested. The majority of applications are covered by the Rockwell C and B scales for testing
steel, brass, and other materials.

If indentation is placed too close to the edge of specimen, the specimen edge will bulge,
and the hardness number will decrease accordingly. To ensure an accurate test, the distance from
the center of the indentation to the edge of the specimen must be at least one and half to two
diameters of the indenter.
An indentation hardness test cold works the surrounding material. If another
indentation is placed within this cold worked area, the reading usually will be higher than the
real value. Generally, the softer the material, the more critical the spacing of indentations
becomes. However, a distance of three diameters from the center of one indentation to another is
sufficient for most materials.

Schematic Diagram of Rockwell Hardness Test

Typical Application of Rockwell Hardness Scales

HRA . . . . Cemented carbides, thin steel and shallow case hardened steel

HRB . . . . Copper alloys, soft steels, aluminium alloys, malleable irons, etc.

HRC . . . . Steel, hard cast irons, case hardened steel and other materials harder than 100 HRB
HRD . . . . Thin steel and medium case hardened steel and pearlitic malleable iron
HRE . . . . Cast iron, aluminium and magnesium alloys, bearing metals

HRF . . . . Annealed copper alloys, thin soft sheet metals

HRG . . . . Phosphor bronze, beryllium copper, malleable irons

HRH . . . . Aluminium, zinc, lead
Important ASTM Standards

E10: Standard Test Method for Brinell Hardness of Metallic Materials.

E18: Standard Test Method for Rockwell Hardness and Rockwell Superficial Hardness
of metallic Materials.
E140: Standard Hardness Conversion Tables for Metals (Relationships among Brinell
Hardness, Vickers Hardness, Rockwell Hardness, Rockwell Superficial Hardness, and Knoop
Hardness).



The student is advised to prepare his report of the experiment with the following items in
that order: Aim, Procedure, Table of Readings, Calculations, Figure (on the left
page), and Conclusions.

Aim: To conduct hardness test on the Rockwell Hardness Testing Machine

Produre:

Table of Readings


Steel Aluminum
Load (kg)

Indenter Size/Type

Rockwell Scale


Rockwell Number (Average of
three readings)

Equivalent Brinell hardness
(Use tables)




Calculations: <to be furnished by the student in the report>

Figure: is to be drawn on the other side of the page.
Conclusions: <to be furnished by the student in the report>

(b) Brinnel Hardness Testing
Introduction

Hardness is defined as the resistance to scratching in its fundamental definition and the
same definition is implemented in Mhos scale for testing the hardness of materials by relative
scratching resistance. In Mechanical Engineering applications, the hardness is more often
measured as resistance to indentation. The higher the hardness, the better wear resistance the
material has. Hence hard materials find applications in cutting tools, bearings, cutter edges, and
frequently rubbed surfaces in machine elements.

Brinell Hardness Tester

Brinell hardness testing machine is normally used for medium hardness materials,
particularly ferrous and non-ferrous metals and their alloys. A spherical ball is used as indenter.
The ball may be made of either high carbon steel or tungsten carbide. Steel ball may be used for
soft steels and non-ferrous metals and alloys whereas the tungsten carbide ball may be used for
relatively harder materials like medium carbon steel and non-ferrous alloys. Most Brinell
machines provide two combinations of ball diameter and indentation load to be applied. The first
combination is 10 mm ball and 3000 kgf load and the second combination is 5 mm ball and 750
kgf load. The load (P) can be calculated by using the formula of P=30D
2
kgf for steel specimen
material, where D is the diameter of the ball indenter. The indentation load is applied by a
hydraulic system that assesses the load to be applied by means of a lever principle proportional
to equivalent weights hung on the other side of a lever, on the back side of the machine. The
hardness is calculated as the force applied divided by the surface area of the indentation. Modern
Brinell hardness machines come with fully computerized equipment wherein a CCD camera
captures the indentation impressions and sends the same to the online computers software that
is capable of determining the average diameter (d) of the indentation and calculate the hardness
from the following relationship.



The test duration normally varies between 10 to 30 seconds. When a CCD camera is used to
estimate the hardness number in semi-automatic way, surface finish requirements are very
stringent because the indentation diameter may not be captured properly by the computer
software unless the impression is clearly distinct from the surrounding area. Therefore, ample
finishing of the surface is recommended before carrying out the test.

Test Procedure and Record Making

In the following sub-sections the test procedure and record making steps are described.

Aim

To measure the hardness of a given specimen using Brinell hardness testing machine.

Accessories

Power operated Brinell Hardness Testing Machine, Hardened steel ball indenter of 10mm diameter
and specimens (MS,Brass, Al,CI).

Theory

Hardness is the fundamental property of any material which is closely related to strength. It is
usually defined in terms of the ability of a material to resist to scratching, abrasion, indentation
or penetration. The standard Brinell hardness test is conducted as per the ASTM specifications.

The ball indenters are made of either high carbon steel or tungsten carbide. The MCS
Brinell hardness tester model is a production type hardness testing machine designed for
measuring the BHN of steels & other metals flat ,round or irregular in shape. The surface of the
specimen should be free from surface defects, oils, extraneous materials etc.

The Brinell test for hardness consists of the application of steel ball of 10 under a load of
3000kgf for a period of 10 seconds. The loads are gradually applied by means of a hydraulic
mechanism. After full application of load for a given period of time, load is slowly removed .The
indenter is taken out and the diameter of spherical impression is measured.

From the Diameter of projected impression, the area of indentation can be calculated.

D =Diameter of indenter, d = Diameter of thespherical impression, P = Applied load


The student has to write his report on this test as per the following details.

Aim: To conduct Brinell hardness test on the mild steel flat specimen, display the indentation on
the computer screen, measure the dimensions of the same and estimate the BHN through the
software. Also check this BHN by calculating using the formula

Procedure:

1. The specimen is supported on the hardened steel platen located by a robust steel screw which
is adjusted by means of hand wheel.
2. An adjusting wheel on the indenter column enables the ball holder to be brought into contact
with the specimen.
3. The l oad P is applied by means of a simple lever mounted on the knife edges, which
carries a hanger for loose weights ranging from 250kgf to 3000kgf.
4. Steel Ball holder of 10mm diameter and a load of 3000kgf are to be selected in this test.
5. Start the motor and wait until the weight hanger reaches its top position.
6. Turn the hand wheel in clock wise direction so the specimen will get clamped against
clamping cone with slight pressure.
7. Turn the hand lever from unload position to load position so that total load is is applied on
the specimen.
8. When the dial gauge reaches a steady position the load application is continued upto 10 to
15 seconds.
9. Release the load by bringing the lever to unload position and the weights are lowered and
indicator will come to rest.
10. After positioning the lever to Read position indenter will get swiveled and diameter of
indentation will be projected on the computer monitor.
11. Measure the diameter of the indentation using the steps suggested by the software and note
down the Brinell Hardness Number.

Table of Readings:

S. No Material Load on
Specimen(Kgf)
Ball Diameter
(mm)
Impression
diameter (mm)
BHN


Calculations: <calculated BHN from formula to be furnished by the student in the
report with all calculation steps>

Figure: <neat sketch of the indentation, indentor and formula may be shown on the
other side of the page by the student in the report>

Conclusions: <to be furnished by the student in the report>