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FP 740 2.0909
Intelligent Testing
This brochure provides an overview The brochure therefore shows only
of instruments, machines, systems part of Zwick Roell AG’s compre-
and services available from hensive overall range.
Zwick Roell AG for testing products
from the medical technology and
pharmaceutical industries and their
use in R&D, production, quality as-
surance and control, and in testing
institutes and training centers.
Table of Contents
1 The Zwick Roell Group ..................................................................................................................................... 3
2
1 Zwick Roell AG – Over a These companies have comprised Zwick’s years of accumulated
Century of Experience in the Zwick Roell Group since 1992. experience are reinforced by a
Materials Testing July 2001 saw the group become a policy of maintaining regular contact
corporation under the name of with our many customers. This
Mechanical testing is one of the Zwick Roell AG, incorporating Zwick, provides a solid platform from which
oldest forms of materials testing. Da Toni Technik and Indentec Ltd. the company supplies a wide range
Vinci and Galileo were already Between them these companies of products – from economical
turning their attention to bending provide a comprehensive materials, standard machines to customized
strain and the elastic properties of construction materials and function versions for specialized testing
materials in the 15th and 16th cen- testing program – from manually situations. State-of-the-art engi-
turies. Time brought new insights, operated hardness testing instru- neering, powerful electronics and
culminating in the appearance of the ments to complex systems for application-orientated software are
first testing machines in 18th-century process-parallel applications. Acmel the keynote of these modern, versa-
France. Labo, the French manufacturer of tile, highly intelligent testing
laboratory instruments for the machines and systems.
Roell & Korthaus have been involved cement, lime and plaster industry,
in materials testing since 1920, while has been part of the group since Zwick Roell AG is far more than just
Zwick began building machines and May 2002. a manufacturer, however. As long
instruments for mechanical materials ago as 1994 the company received
testing in 1937. Many years earlier, Zwick Roell AG’s expertise in sensor DIN EN ISO 9001 certification - a
in 1876, Professor Seger had technology for load and extension guarantee of consistently high prod-
established a chemical laboratory measurement was enhanced and uct and service quality. In addition,
providing scientific advice on a consolidated by the acquisition of accredited calibration laboratories
commercial basis to the stone German company GTM in 2007 and allow companies in the Group to
industry. During the 20th century this Messphysik of Austria in 2006. inspect and calibrate test equipment
evolved into the present-day and provide internationally recog-
concern Toni Technik, leading nized certification.
specialists in the field of construction
materials testing systems.
Fig 1: Zwick Roell AG and Zwick GmbH & Co. KG: Administration Building, Ulm, Germany
3
2 Zwick – The Specialist comprehensive service portfolio At universities and other educational
for Medical Testing allows the special needs of medical institutes throughout the world,
Solutions engineering and pharmaceuticals to Zwick supports ground-breaking
be catered for. research with tailor-made solutions.
Medical engineering has joined ma- In addition to serving in testing and
terials testing in the metals and Customized Solutions for research laboratories in education
plastics industries in becoming an Maximum Flexibility and industry, Zwick materials testing
increasingly significant part of machines can also be found
Zwick’s activities. In the last four Zwick provides solutions tailored to integrated into production lines for in-
years alone the number of orders the requirements of customers from process checks. Our testing
received from this field has doubled. the medical technology and pharma- instruments and systems can also
Safety requirements occupy an even ceutical industries. The majority of be combined with automatic
more prominent position in medical materials testing machines installed specimen feeders, their modular
technology than in most other indus- in this sector are customized design allowing them to be
tries, simply because the products designs; test fixtures in particular expanded and adapted to new
have a direct influence on human must be adapted on an individual situations as required.
beings. To meet these requirements, basis to suit the product in question.
quality testing naturally includes de- The wide degree of freedom offered Zwick is a member of numerous
velopment, production and pack- by testXpert® II software is of great associations, bodies and networks
aging of medical products, paying value in meeting varying testing and is continually adding to its fund
due attention to legal requirements requirements and Zwick provides of experience by sharing and
and relevant standards; most im- suitable software functions and exchanging information with various
portantly, it must also minimize the detailed documentation to facilitate committees and collaborators.
risk for patients and users. validation in this heavily regulated
sector.
No Matter what Segment of
Medical Technology – Zwick
has the Solution
4
2.1 Medical Packaging Push-out Test on Blister Packs
Products from the medical tech- The spherical laser-pointer die can
nology and pharmaceutical industries also be used for positioning speci-
must be securely packed and also mens from other push-out tests.
ensure product safety over a longer The compression die is designed for
storage period. Packaging is manu- a maximum force of 30 N.
factured from a wide variety of
materials, in various geometric forms
and may be equipped with special Peel Test on Peel and Blister Fig. 2: Testing device with laser positioning
functions. Packs for push-out test
5
Special Non-destructive
Compression-test Kit for
Medical Injection Vials
Fig. 1: zwicki-Line materials testing machine with residual seal force testing device
6
Compression Test on Card- Tear Test
board Packaging Standards ISO 34-1, ISO 6383-1,
EN 495-2 and DIN 53363 relate to
Compression tests have various pur- tear tests on plastic foils. The test
poses, two of which are described simulates the behaviour of packag-
below. ing foils when the package is opened.
Push & Turn Test on Screw Caps and an additional torsion drive of 5 Nm
torque are used. The two test axes
Test to determine the superimposed can be used for independent or
compression / torsional forces on combined axial / torsion tests as
opening and closing of childproof required, the package being opened
containers or pharmaceutical pack- via a rotary movement with a super-
aging. For this a zwicki-Line table- imposed axial loading. Important
top testing machine of Fmax 2.5 kN parameters are the opening torque
required and the functioning of the
childproof mechanism.
Fig. 1: zwicki-Line Torsion for push & turn Fig. 3: Testing sealed seam strength
tests on pharmaceutical packaging
7
2.2 Therapy Systems Testing Catheter Connections
A 2-point flexure test kit for deter- This device enables tests to
mining the kink resistance of guide DIN EN ISO 11499 on dental syringe
wires, designed for forces up to 50 N. cartridges for local anesthesia to be
Grip-to-grip separation is infinitely performed and is used to determine
adjustable and the kit includes a dial the force required to move the
gage for displaying grip-to-grip plunger in the cartridge. It can also
separation from 0 to 55 mm, with an be used for additional tests, e.g.
accuracy of 0.1 mm. Specimen testing leakage on syringe cartridges.
clamping is in the vertical plane, with The test fixture has a clamping
the bending angle (max. 90°) gene- device with prism jaws, a compres-
rated via the rotating clamping unit. sion die and drain hole in the lower
part of the test arrangement, while a
protective container provides
shielding from slivers and acts as a
fluid collector.
8
Testing Luer-lock Connections Test Device with Fluid Reser-
voir for Determining Plunger
With catheter connections, as used Actuation Force
with infusion needles, it is important
that connections between individual This device was developed to
components can be made simply determine the forces required to
and reliably. These tests can be actuate the plunger of sterile single-
performed with (for example) a Zwick use hypodermic syringes (with con-
Z020 testing machine with 500 Nm tents as appropriate) in tests to
torsion testing device attached. It is DIN EN ISO 7886-1 and reproduces
important that compression load, working conditions, i.e. filling and
torque and indentor cone are stand- discharging of fluid. It consists of an
ardized. upper and a lower clamping device
for holding the syringes plus a
height-adjustable fluid reservoir with
connecting tube. The device can be
Fig. 2: Testing luer-lock connections easily dismantled for cleaning.
This test device has been designed This device comprises an AllroundLine
especially for determining penetration table-top testing machine expanded
force and advancement force of to 8 test axes to hold 8 load cells. It
cannulae and hypodermic needles is equally suitable for use in the labo-
up to 200 N following LAB 530. For ratory or for in-process monitoring
this the force/distance during the and is used for testing the various
various phases of the injection is frictional forces between syringe
recorded. The upper clamping fixture plunger and cylinder, or the sealing
can also hold hypodermic syringes rings in syringe cylinders. The syringe Fig. 4: Determining hypodermic plunger
with needles and auto-injectors with holder has acrylic sleeves for actuation force
a specimen diameter of 5 – 10 mm syringes of different sizes, plus two
or 12 – 18 mm. The device also has containers for catching expelled
a lower retainer for the penetration liquids. This device can also be used
material (usually foil) with various for testing frictional forces on cylin-
inserts, ensuring centering of diffe- drical ampoules.
rent types and sizes of needle.
Fig. 1: Foil retainer for penetration force Fig. 3: Device for simultaneous testing of up
measurement to 8 hypodermics
9
Discharging Testing Device Automatic Testing of Horizontal Test on
for Dosimeters and Syringe Injection Pens Catheter Systems
Cartridges
Zwick’s test device for automated test- Catheters, guidewires and other
This height-adjustable clamping de- ing of injection pens (e.g. insulin pens) minimum invasion instruments pass
vice was designed for testing dosi- is based on a zwicki-Line Z0.5 TN through three distinct phases to
meters and syringe cartridges and is table-top testing machine with addi- follow a tortuous path through an
used to determine discharging forces tional torsion drive, allowing the artificial aorta. The various catheter
and volumes. Scales for measuring various operations of the pen to be forces can be measured in each of
expelled volumes are positioned in tested using a single device. In this these phases – insertion into the
front of the testing machine and are way the dosage setting, release artery in the inguinal region,
shielded from external influences by force, stroke and the dose dispensed straightforward progress along the
an acrylic housing with removable are all measured in one continuous artery and tracking artery curvatures
cover, ensuring reproducible process. The test device can be of more than 90°.
measurement. Carrier sleeves for combined with a robotic specimen
glass cartridges are available as feed system and the test methods • Initial insertion force of catheter
accessories. The device is designed using either or both axes can be • Advancement force
for compression tests up to 100 N combined as required. • Flexibility of catheter tip with
and can also be combined with a curvature greater than 90°
robotic specimen feed system, • Physiological environment through
which thanks to its modular design use of temperature-controlled
can be expanded and adapted as water-bath using various media
required to accommodate a wide (pH value).
variety of testing situations.
Development work on these cath-
eter and guide wire systems includes
attempts to reduce the co-efficient
of friction and the breakaway torque.
The horizontal Allround-Line testing
machine offered by Zwick enables
determination of shear forces in a
simulated catheter insertion with
very high accuracy. The test is
carried out in a horizontal orientation
in order to simulate the physiological
Fig. 2: zwicki-Line materials testing status of the patient during the
machine with integrated torsion drive for surgical intervention.
automatic testing of injection pens
Fig. 3: Horizontal testing machine with integrated bath for catheter testing
10
2.3 Surgical Instruments Tensile Test on Metals and For a further test of saw blade
Metal Alloys flexure strength, installation of a 3-
point flexure test kit from the Zwick
High-grade steel, high-tensile steel accessory range is quick and
and titanium alloys are tested on a straightforward. These tests allow
daily basis in incoming inspection or the cutting characteristics and
in materials laboratories of medical precision of different saw tooth
concerns by means of the classical geometries to be investigated.
tensile test. To determine the strength
and deformation behavior of metals Bone Drill Penetration Test
or components they are subjected to
tensile, flexural and compression Today’s bone drills face exacting
Medical / surgical instruments are loadings. The requirements for this requirements with regard to cutting
found in a wide variety of materials are specified in various standards, edge characteristics, contact force
or combinations with widely differing including ISO 6892, EN 10002, required, chemical resistance and
geometrical forms and can combine JIS Z 2241, ASTM A 370, and avoiding bone heating. This test
many different functions in one ASTM E8. Zwick supplies appropriate device is used to determine contact
instrument. testing machines, extensometers force, penetration force and torque
(mechanical and optical), specimen required for a bone drill. Depending
Hardness Test grips, accessories and Master Test on the area of use and the bone
Programs with parameters already quality involved, dental drills, cortical
To test the hardness of metals or pre-defined to the specifications of drills, oral surgery drills etc. are
components used in surgical the relevant standards for virtually all screwed into the appropriate materi-
instruments, hardness testing testing requirements. al – dentine, bone or substitutes –
methods to Rockwell, Brinell and using a specified feed pressure and
Vickers (Knoop) or the modern Compression Test on Sagittal torque.
instrumented indentation method Saw Blade
(Martens hardness) are used. The test allows overlaid measure-
The cutting precision and flexural ment of torque and compression
strength of sagittal saw blades have force. Zwick’s comprehensive
a significant influence on operation testing machine concept additionally
outcomes. Function testing these provides flexure fatigue resistance
saw blades involves simulation of testing via a 3-point flexure test kit
handling by the surgeon. The com- plus hardness testing of the basic
plete saw plus blade is clamped in material.
the testing machine, the saw is
started and the blade is run against
the bone substitute material. Press-
ing force and depth of cut are meas-
ured, to provide tolerance values for
correct use; calculated characteristic
values, such as stiffness, provide
information regarding load influences
which will bend or damage the saw
blade.
Fig. 1: Device for compression tests on sa- Fig. 2: Penetration test on bone drill
gittal saw blades
11
2.4 Biomaterials
12
Tensile Test on Artificial Tissue Testing Scaffolds for Bone
in Temperature-controlled Replacement
Environment
Research into biomaterials requires
Rapidly absorbable materials such as the test environment to correspond
those increasingly used today in to actual conditions as far as
traumatology, surgery and wound- possible. For this reason testing in
healing change their material proper- this field is preferably carried out in
ties progressively on contact with fluid baths or complete incubators.
media such as blood, water or saline
solution. This must be controllable so In this application, cells from bone
that absorbable biomaterials can be marrow are applied to a carrier ma-
used in a targeted way. It is important terial and cultivated in a liquid
during manufacture and develop- nutrient under cyclic mechanical
ment to be aware of the change in stimulation. For this an ambient
rigidity, tensile strength and proof temperature of 37 °C, 100%
stress (yield point) and where neces- humidity and cyclic loading (using
sary to adjust it. Zwick testing actuator) under very
low forces are necessary.
A temperature-controlled fluid bath
has been added to Zwick’s bio- The load is applied to the specimen
mechanics accessory range, making via a die integrated into the incu-
it possible to simulate an in-vivo Fig. 1: zwicki-Line with temperature- bator from above and the specimens
environment for tests on tissues. controlled fluid bath and videoXtens (bath immersed in the liquid nutrient are
lowered for specimen change)
Suitable submersible accessories for flushed with CO2 or N2 to adjust
specimen fixing are also available. the pH value. Extensions lie between
30 and 100 µm.
Principal Features
• Z2.5TN table-top testing machine,
Fmax 2.5 kN.
• Test speed: 0.001 - 1000 mm/min.
• Temperature-controlled bath with
separate heating circuit.
• Pre-conditioning of specimen in
temperature-controlled bath
available.
• Optionally available: videoXtens or
submersible clip-on extensometer
and various submersible specimen
grips.
13
2.5 Biomechanics Testing Anchoring of a
Hip Endoprosthesis
Stapes prostheses are used in Ear, Here a bone screw is screwed into
Nose and Throat (ENT) therapy as a bone replacement material by
replacement for the stirrup, the means of a torsion drive. The rele-
prosthesis forming a direct connec- vant parameters here are the torque
tion between hammer and inner ear. required in conjunction with the
The ball-joint allows optimum applied compression force.
matching during the operation. To
ensure functional integrity, the joint The testing machine used is a
force must only move in a specified zwicki-Line Torsion (5 kN nominal
area. The prosthesis is only 5 mm in force, 20 Nm torsion drive).
length and has a diameter of 0.5
mm. Using the zwicki-Line Z0.5
table-top testing machine, this force
can be determined without damage
occurring to the specimen.
14
Fatigue Testing on Torsion Test on Fatigue Test on
Spinal Implants Artificial Ball-joints Hip-joint Prostheses
In spinal surgery, stabilization of the Artificial hip-joints must withstand The Zwick Amsler HC Compact
spine is achieved via a movable (disc both compressive loads and torsion servo-hydraulic testing machine is
prosthesis) or fixed (cage) interver- loads. used to simulate dynamic loadings
tebral disc replacement. In addition, on a hip prosthesis stem in accor-
a stiffening operation using screws To determine the optimum materials dance with the relevant standards,
and rods, or the replacement of an and alloys, these are tested with a ISO 7206-4, ISO 7206-6, ISO 7206-8
entire vertebral body with a vertebral special testing unit consisting of a and ASTM F 2068. Use of the ap-
body replacement implant can be 20 kN capacity Zwick materials test- propriate embedding device enables
employed for stabilization. ing machine plus a 500 Nm torsion the mechanical conditions specified
drive. in the standard, such as the orien-
All spinal implants have one thing in tation of the hip-joint prosthesis to
common – they must withstand all The artificial hip-joint (here made of the test load or the embedding
dynamic loads over many years. metal) is rotated on a support unit height, together with the angle of
(torsion loading) and at the same load application, to be defined
Tests of this kind can be performed time compression loading is applied. exactly.
with the LTM1000 linear drive testing
machine or with the Amsler HC-T To test the durability of the stem,
servo-hydraulic testing machine with dynamic loading on the hip-joint
additional torsion components. In prosthesis during walking, with
this way, for example, ISO 12189, loosening already present, is
ASTM F 2077, ASTM F 2347 or the simulated; by contrast, the neck
FDA Guidance specifications, which region of the prosthesis, which is
describe dynamic compression, clinically well anchored, is subjected
shear or torsion tests, can be to alternating loading. The Zwick
implemented in compliance with software also allows operator-friendly
standards. Locati tests to be performed.
Fig. 1: LTM1000 with spinal implant Fig. 3: Test device for holding hip-joint
prostheses
15
Fatigue Test on Lower Leg
Prosthesis
Principal Features
• Servo-hydraulic HC 10 for dynamic
testing up to Fmax 10 kN
• Testing frequencies up to 100 Hz
• Extremely stiff and fatigue-resistant
design
• Servo-hydraulic testing machine
for tensile, compression and
flexure tests
• Suitable for continuous, static,
pulsating and alternating loading in Fig. 1: Test device for lower-leg prostheses
quasi-static and dynamic tests
• Piston stroke 400 mm with end-
position damping Simultaneous Fatigue Tests on
• Customized holders for leg 30 Stents
prostheses
• T-slot table To investigate the durability of stents
• HydroWin measurement and a fixture has been developed which
control electronics allows up to 30 stents to be ac-
• testXpert® and Workshop user commodated simultaneously. This
programs fixture, with an electric torsion drive
(1 Nm), is used in combination with
Advantages and Benefits for Fig. 2: Test device for stents an HC 10 servo-hydraulic testing
the Customer machine (10 kN) and allows both se-
• Simple, reliable operation via parate and superimposed loading of
proven software-controller the stents with compression and
combination torsion (5 Hz at ± 60°). The gripped
• Universal clamping options via T- area of the stents can also be
slot table and easy fixture change provided with a fluid bath to enable
• Extremely stiff, robust design testing under physiological
intended for continuous loading at conditions.
nominal force
• Tailor-made solutions are no
problem thanks to a wide range of
options Fig. 3: Nitinol stent
16
2.6 Clinical Research Flexure Test on Sheep Bones
17
2.7 Textile Medical Products Unrolling Test for
Gauze Bandages
18
Testing Non-wovens used in the Measured value is maximum tensile
Medical Field force. The coefficient of variation for
the results is calculated. Other
These materials are often used as important test methods include
wound dressings and as a compo- absorption capacity (EN ISO 9073-6)
nent part of dressing materials, as and strike-through time for liquids
an alcohol swab for preparing (EN ISO 9073-8). A zwicki or ProLine
injections or in physiotherapeutic (Z005) testing machine is typically
applications; they are a component used for these tests.
part of patient and instrument
drapes in the operating theater and
used as a cover for dental tampons.
Fig. 1: Specimen grips for yarns Fig. 3: Testing seam slippage resistance Standards EN 13795 and EN 14863
provide manufacturers with guide-
lines and common reference require-
ments to be met by surgical textiles.
19
2.8 Silicone Products So that they do not tear when being Tensile Test on Condoms
pulled on in use, the gloves must
display sufficiently elastic behavior. zwicki-Line table-top testing ma-
chines are suitable for determining
Examples of stresses to which they the tear strength and strain at tear
are subjected include hooking on or of condoms. The required force
holding pointed or sharp tools, for- measurement range as specified in
eign bodies or instruments. Methods the standard lies between 0 - 200 N
used to guarantee the required and the load cell suitable for this
operational reliability, include the has a nominal force of 200 N (meas-
following mechanical tests. uring range from 2 N in Class 1 to
DIN EN 10002-2). The crosshead
Many medical products are made of Tear-strength tests are performed on speed is 500±50 mm/min.
latex, rubber or silicone, the elastic gloves with and without a seam, as
properties of these materials being well as on artificially aged gloves. Flanged rollers, arranged horizontally
useful in this field, while their non- zwicki-Line or ProLine testing ma- and mounted at one end only, are
toxicity especially that of natural chines are also used for this and used to hold the specimens. One of
latex, plays an important role in testing takes place to ISO 37 and these rollers is driven via a toothed
medicine and hygiene in excluding ASTM D412. Three shouldered test belt proportionally to the crosshead
germs. bars are punched out of the palm, movement, loading the condom
back and cuff of the random sample specimen uniformly over its entire
Tensile Test on Rubber Gloves glove, parallel to the longitudinal axis circumference. If the rollers were
and avoiding structured areas. fixed or not driven, frictional forces
Single-use medical gloves provide would act in addition to the tensile
protection in operations, exami- force and the specimen could be
nations and caring activities. The unacceptably loaded and pre-
most important requirement is damaged.
preventing the entry of air, fluids and
micro-organisms. Manufacture in- A thickness-measuring device can
volves immersing molds in solutions be connected via the serial port of
of natural rubber or latex mixtures. the PC, so that these measured
The number of immersion and drying values are automatically input into
processes is repeated until the the test as well.
required thickness is achieved, after
which the gloves are vulcanized in
curing ovens.
Fig. 1: Tensile test on rubber raw material Fig. 2: Roller specimen grips for testing
condom material
20
2.9 Dental Industry 4-point Flexure Test Kit for Fatigue Test on Dental
Tests on Ceramics Materials
(Chewing simulator)
• Die and lower bending table for
4-point flexure tests for tests on For tests on teeth, dental prostheses
dental ceramics to ISO 6872 and and filling materials a test stand
on advanced technical ceramics based on the HCT-10 servo-hydraulic
to EN 843-1 Specimen Shape A testing machine has been developed
• Die and bending table each which enables dynamic loading with
consist of 2 hardened anvils with an axial force up to 10 kN and
rollers with adjustable span torque up to 100 Nm. Up to 5 speci-
• All rollers can be rotated, with mens can be in a water-bath at the
Materials (ceramics and metals), swiveling or fixed mountings as same time and are loaded with a
composite materials and adhesive required (lockable via pins) testing frequency of up to 25 Hz
bonds used in the dental industry, • Can also be used as 3-point axially, torsionally or with a trans-
together with dental prosthesis flexure test kit via simple verse movement via an adaptable
systems, are tested for their hard- modification test piece. The forces are recorded
ness, strength and fatigue limit. by a load cell placed between
actuator piston and die or via 3-
Hardness Test on Dental component load cells underneath
Ceramics the water-bath.
21
3 Zwick Modular System for Individual Testing Requirements
Material testing Biaxial testing Servo-hydraulic Vibrophores Hardness testers Vicat testers
machines machines testing machines
+ testXpert® II
Medical option
testXpert® II testControl
22
3.1 Quasi-Static Materials • The zwicki-Line consists of high-
Testing: Products and Ser- quality, compact machines. These
vices portable, easy-to-use single-column
load-frames have been specially
Materials Testing Machines designed for mechanical testing
with low test loads of 0.5 to 5 kN.
Applications
Materials testing machines are used • The ProLine was developed to
to determine the strength and de- satisfy the demand for cost-
formation behavior of specimens and effective testing machines for
components, mostly under tensile, function- testing components and
compression and flexure loading. standard tests on materials. The
Shear and torsion loads are also ‘Pure Portfolio’ accessory range
used. These testing machines fea- for the ProLine ensures an attrac-
ture long travel, wide test-speed tively priced system and short
ranges and interchangeable sensors delivery times. Test loads are from
and tools, allowing testing of speci- 5 kN to 100 kN.
mens and components with widely
differing forms and dimensions, • The Allround-Line provides the
made from various materials and solution to challenging testing
materials combinations and with situations and fulfils the most ex-
correspondingly different character- acting requirements. It can be
istics. equipped or upgraded via a com- Fig 2: ProLine Z050TN with CE conforming
prehensive accessory range and protective screen
Basic Concept used with special sensors and
Zwick has three series of quasistatic multi-channel measuring technol- zwicki-Line Single-column
materials testing machines, differing ogy. Model
in design, equipment, performance This load frame is based on a highly
characteristics and expandability. Load Frames bend-resistant aluminum extrusion,
This allows us to provide the most Our standard production load frames which was developed especially
suitable machine for every budget. are rated for loads up to 2000 kN. for the zwicki-Line. The workspace
We design and manufacture special is freely accessible from three
versions for specific applications, e.g. directions, making the zwicki-Line
for higher rated loads or horizontally also suitable for small component
aligned load frames for testing in the testing and for use as a hardness
component installation position. tester. This modular system’s low
weight and compact base make it
easily portable – and it will fit on any
laboratory table.
23
Allround-Line Table-top and Hard-chrome plated guide columns Hydraulic Drives
Floor-standing Testing Machines and a precision ball screw with play- This drive is located centrally to the
The table-top testing machines are free spindle nuts guarantee a high fixed crosshead, making the test
equipped with two columns made of level of precision for the floor-standing area below easily accessible. A
patented extruded aluminum. They machines. Various crosshead con- servo or proportional valve regulates
are light and highly bend-resistant figurations are available, providing the oil flow between the hydraulic
and combine the functions of spindle either an upper or lower test area – unit and differential cylinder. The oil
guide and spindle protection. T-slots or both. All load frames with electro- pad in the upper pressure chamber
on the outer sides allow simple mechanical drives can optionally be eliminates the familiar problem of
mounting of accessories such as equipped with a second test area. plunger pistons “jumping” when a
fixtures or safety guards, unrestricted Benefits include rapid change to a specimen breaks. For high test loads
by the moving crosshead. different type of test without having in particular, the hydraulic drive is an
to reconfigure the entire machine. extremely cost-effective solution.
All table-top testing machines can
be fitted with stands to bring the Drives for Quasi-static Test Hybrid Drives
workspace to the optimum height Situations These patented drives combine the
for the application or operator. This advantages of the electromechanical
allows, for example, comfortable Electromechanical Drives drive (high precision) with those of
seated operation with plenty of All electromechanical drives incor- the hydraulic drive (high forces). As a
legroom, making the system well porate play-free, low-wear ball result, even long-stroke cylinders
suited to wheelchair users also. screws and digitally controlled drives designed for very high loads can be
and are used with load frames rated moved and positioned very precisely.
for test loads up to 2000 kN. This approach allows two parallel
Combined with the digital measure- mounted cylinders coupled to the
ment and control system, they offer moving crosshead to be traversed
the following advantages: with precise synchronism and
regardless of their respective
• Extremely wide, infinitely variable loadings. They follow, accurately
speed-range and virtually without hesitation, the
• Very low speed-settings possible position parameters set by an
(from about 0.5 µm/min) electromechanical pilot drive. Special
• Highly precise, exactly reproducible features of this drive:
positioning and speeds
• Long travel range (no adjustment
The ProLine and zwicki-Line testing of fixed crosshead necessary
machines are fitted with DC motors. • Relatively low load-frame height
All other testing machines have
especially low-inertia brushless three-
phase AC motors.
24
Biaxial Materials Testing
Machines
Specifications
Force measurement range per load
cell: +/- 100 N
Fig. 2: Strain measurement with laserXtens Force signal resolution: 0.6 mN
(laser-speckle principle) Travel: 50 mm
Displacement measurement
Possible Applications resolution: 0.1 µm
• Planar mechanical test Maximum speed: 2000 mm/min.
• Uniaxial, equibiaxial, non-uniform
loading
• Determination of mechanical
properties of elastic tissues.
25
Drive Axes as Individual and Electromechanical Servo Torsion Drives
Expansion Solutions Testing Actuator
Torsion drives from 2 Nm to 2000 Nm
Additional Zwick drive axes can be Zwick’s full range of electromechani- are available for the various materials
used as a flexible individual or cal servo testing actuators combine testing machines for tests on com-
expansion solution for materials versatility in use and high travel ac- ponents or materials which include
testing machines. Combining several curacy with high test speeds. They torsion loading in addition to tensile/
drive axes is also possible. require no special hydraulic equip- compression loading.
ment or power packs, are a cost-
effective solution for quasi-static and The torsion drives were developed
cyclic component testing and are as a modular system and can there-
compatible with testControl and fore also be retrofitted. In addition to
testXpert®. a testXpert® II Master Test Program
for multiple test axes, a graphical
They can be used in many different sequence editor for four test axes is
situations, being available in a load also available.
range from 1 – 30 kN, with stroke
from 200 – 400 mm. Their speed For pure torsion tests there are the
range is between 26 and 500 mm/s. TorsionLine testing machines, which
cover a torque range from 20 to
Pneumatic Testing Actuator 2000 Nm.
Fig. 2: Electromechanical servo testing Fig. 3: zwicki-Line with torsion drive Fig. 4: Allround-Line with torsion drive
actuator with external fixation of fractures
26
Hardness Testing indenter, while the automatic test
sequence and predetermined time
ZHU/zwicki-Line Universal frame eliminate operator influence
Hardness Testing Machine during hold time.
Based on the zwicki-Line, the ZHU/
Z2.5 universal hardness testing ZHV-s (semi-automatic) / ZHV-a (fully
machine can, in addition to the automatic) – both feature completely
classic Rockwell, Vickers, Knoop, automatic operation to the user's
Brinell and ball indentation hardness specifications. The semi-automatic
testing methods, be used for the in- version differs in having manual
novative instrumented indentation indentation focusing against motor-
test for determining hardness plus ized auto-focusing. Motorized load-
additional materials parameters of change, automatic indentation
metallic materials (so-called Martens measuring, automatically controlled
hardness, DIN EN ISO 14577). Install turret (via testXpert®) for exchanging
the patented hardness measuring indenter and lens positions,
head (resolution 0.02 µm) with motorized cross-table and fully
integrated digital depth and load automatic test sequences – uses
measurement system in a zwicki- include hardness profile tests with
Line materials testing machine with multiple sequences.
modified drive, add state-of-the-art Fig. 1: Zwick/ZHU2.5/Z2.5 fully automatic
testControl measurement and universal hardness testing machine with
motorized displacement unit
control electronics and testXpert® in-
telligent testing software and the
result is an ideally balanced high- Zwick/ZHV1 and ZHV2 Micro-
precision measuring system. Vickers Hardness Testers
Zwick micro-Vickers hardness
The ZHU/zwicki-Line can be testers cover the load range from
upgraded to a fully automatic unit HV0.01 to HV2 and support the
with motorized linear displacement following standards:
unit controlled via testXpert®, • Vickers (HV) to DIN EN ISO 6507,
eliminating potential operator errors. ASTM E 92
• Knoop (HK) to DIN EN ISO 4545,
Vickers Hardness Testers ASTM E 384.
The range of Vickers hardness
testers covers various load ranges For both load ranges there is a
with differing levels of operator choice of operating concept:
convenience, allowing the right
instrument to be selected for every ZHV-m (manual) – measuring is
application. performed manually by the operator,
using a microscope. The automatic Fig. 2: Indentation cone after Vickers
turret allows one-button control hardness test
when changing between lens and
27
3.2 Fatigue and Impact • T-slot platform hard-chromed for
Testing: Products and Ser- tests with corrosive media, e.g.
vices saline solutions
• Seal-free testing actuator with
Fatigue Testing Machines hydrostatic bearings, guaranteeing
significantly longer maintenance-
Servo-hydraulic Testing free operation than with any other
Machines design.
Servo-hydraulic testing machines are
universally applicable for materials Amsler HCT and HBT Tensile
and component testing under pul- and Compression/Torsion
sating or alternating load, with Testing Machines
periodic or random signals. Quasi- The servo-hydraulic testing ma-
static and continuous loading are chines in the Amsler HCT and HBT
also easily achieved. series are used to test the behavior
of materials and components under
Special Features combined tensile and compression/
• Precisely aligned load frames torsion loading. The tests can be
featuring extremely high stiffness performed with pulsating, cycling
• Hydrostatic bearings, making the and static loading.
actuators virtually frictionless – and
also wear-free
• LVDT extensometer with high
resolution and linearity integrated
centrally in the actuator rod Fig 1: Servo-hydraulic testing machine
• Precision strain-gage load-cell for Amsler HCT 10/100
mounting on actuator rod or fixing
to crosshead as required
• Wide range of hydraulic power Amsler HC-compact
packs The Amsler HC-compact servohy-
• Comprehensive range of acces- draulic testing machine consists of a
sories (specimen grips, extensom- hydraulic power pack, test frame
eters, temperature chambers etc.) and test actuator and is suitable for
materials and component testing
under static and oscillating loads.
Advantages
• Space-saving design with inte-
grated hydraulic power pack
Specifications • Whisper-quiet power pack allowing
Model HC installation without additional noise
• Type/version table protection measures in virtually any
• Load frame laboratory
nominal force [kN] 10 – 25 • Testing actuator mounted in top
• Test stroke [mm] 100/250 crosshead permitting easy set-up
• Specimen length [mm] 100 – 700 for flexure and component testing
• Hydraulic power pack
System pressure [bar] 210/280
Feed rate [l/min] 9 – 30
• Motor nominal power [kW] 5 – 20 Fig 2: Servo-hydraulic testing machine
Amsler HC-compact
28
LTM1000 Materials Testing Advantages Features
Machine with Linear Drive • Piston stroke measurement • Long stroke for fatigue and static
directly adjacent to the specimen testing over a wide range of
Developed for quasi-static and fa- eliminates the need for separate applications
tigue tests on materials and compo- extensometers in many • Precision, low-wear bearings on
nents, Zwick’s testing machine with applications actuator
linear drive is used in industries • Space-saving, low-noise design • High-resolution displacement
which place maximum demands on • No additional fluids such as transducer adjacent to specimen
technology and cost-effectiveness, pneumatics, water or oil required • Easy quick adjustment of test area
such as medical engineering (e.g. • Static tests can also be performed via separate crosshead
implants, dentistry), electrical engi- easily using testXpert® II universal • Intelligent cooling system with
neering (e.g. switches and PCBs) testing software. automatic control
and micromechanics (e.g. miniature • Proven Zwick testControl
components). It is also ideal for electronics
materials development, for example • Intelligent testXpert® II testing
for testing miniature specimens, and software for simple, intuitive
with the addition of suitable attach- operation
ments can be employed for environ-
mental simulations in temperature
chambers and baths. Specifications
Model LTM1000
The linear drive allows high-precision • Stroke [mm] 70 (Amplitude ± 35)
• Continuous force (static) [N] ± 800
testing with excellent dynamic
• Peak force (dynamic) [N] ± 1000
response in a wide range of appli-
cations. This low-maintenance • Frequency [Hz] 10
machine features compact, space- • Weight [kg] approx. 120 (electronics not included)
saving design and a very low noise • Electrical supply requirements [V / kVA] 1x230 / 1.6
level and can quickly be put into
operation. All it requires is an elec-
tricity supply – no need for water, oil
or compressed air.
29
4. System Components
4.1 testXpert® II –
Intelligent and Protected
from Manipulation
Comprehensive User Manage- reports) or Test Programs. In this grams for cyclic tests and tear
ment way you avoid input errors and growth tests also contains the
prevent manipulation. In addition, ‘Expanded Traceability’ option.
Do you wish users only to carry out user management allows password Additionally, Zwick offers customized
functions from a specified range of guidelines to be defined individually. Test Programs which are created
tasks? Or would you like to make according to customers’ specifi-
their work easier by hiding un- Test Programs/Free Sequence cations and/or factory standards.
needed functions in the menu bar? Programming Through extensive testing we can
testXpert® II’s powerful user manage- guarantee that all Standard Modules
ment, which is already contained in testXpert® II already contains pre- will be compatible with earlier ver-
the Basic Program, enables you to pared Standard Test Programs for a sions within the testXpert® II product
do so. multitude of international test stand- range. In research in particular, it is
ards. For the medical and pharma- often necessary to be able to pro-
Choose from default user groups or ceutical industries Zwick has a gram the test sequence freely. In the
define your own; you can authorize specially designed Master Industry testXpert® II Graphical Sequence
or disable individual menu items, Package for medical technology, Editor you have an extremely com-
standard actions (e.g. printing which in addition to Master Test Pro- prehensive tool; simply program the
test sequence you require, using
straightforward function blocks on a
graphic interface.
30
Expanded Traceability
as per FDA
31
4.2 Zwick testControl Many medical applications require interfaces to testControl, external
Measurement and Control additional measurement signals as measurement systems such as the
Electronics well as the usual channels such as HBM MGCplus can be linked.
force and elongation. testControl
Measurement and control electronics offers the flexibility demanded of This gives the further option of
are an essential component of any measuring systems in such applica- quarter, half or full-bridge measure-
testing machine. Their design and tions, whether for applying additional ment of resistances, pressures,
features determine which drive can strain gages to a specimen or si- temperatures, accelerations, and
be operated, which measuring sys- multaneously measuring tempera- single strain gages etc.
tem connected and which functions ture. In addition to these direct
controlled.
± 10V
P I/O F
U I
s R t
Fig 2: Analog and digital signals can be connected to testXpert® and testcontrol
32
4.3 Zwick Extensometers 2007 saw the unveiling of laserXtens,
offering high-resolution (down to
Measuring elongation and/or strain 0.15 µm), contact-free elongation
places extremely high demands on a measurement without the need to
modern testing system. For many attach gage marks to the specimen.
years Zwick has been leading the This system makes completely new
field in developing digital extensom- applications possible, such as the
eters for a wide range of applications. testing of small specimens with gage
lengths down to 1.5 mm. This
Today Zwick has the most compre- technology and heritage allows
hensive range of analog and digital Zwick to provide the optimum
extensometers, both contact and extensometer for every application.
non-contact. In 1998 Zwick had Fig 3: laserXtens with round specimen
developed and introduced the worlds
first digital clip-on extensometer. In
2004 the portfolio of extensometers
was extended with the optiXtens
and multiXtens.
Extenosmeter
Properties
Purchase,
Measuring Priciple, Functionality Environmental
Running Costs,
Properties (auto / manual) conditions
Ease of Use
Extensometer Portfolio
33
4.4 Zwick Specimen Grips Gripping Force 4.5 Load Cells
Zwick’s comprehensive range of Specimen grips with externally Load cells are available for accurate
specimen grips of various designs generated gripping force apply the measurements starting from 0.02 N.
and for differing test load ranges and set force level throughout the test. In combination with testControl digi-
test temperatures covers a wide field Especially with thick or soft speci- tal measurement electronics they
of application. The specific applica- mens, however, specimen material offer the following advantages:
tion range of a specimen grip is can flow out of the grips under the
largely determined by its operating influence of the test load, reducing • Measurement accuracy: Class 1
principle and maximum permitted the specimen thickness. With (1 % of measured value) from 0.2
test load; for tests in a temperature hydraulic and pneumatic specimen to 100 % of nominal force and
or climatic chamber the temperature grips the gripping force remains Class 0.5 (0.5 % of measured
range in which it can be used is also constant, because the pressure value) from 1 to 100 % of nominal
of significance. generator supplies more pressurized force
oil or compressed air. The gripping
Zwick develops customized speci- force of screw grips decreases to • Resistant to parasitic influences
men grips for the medical industry some extent depending on the (bending moments etc.)
which are exactly verfied to the stiffness and resilience of the grips.
customer’s specimen. • High flexural strength limit and tor-
Gripping Surface sional strength limit against break
Load Transfer between
Specimen and Grips Frictional force depends on both the • Zero point and characteristic value
magnitude of the gripping force and temperature compensation over
With most specimens the test load the coefficients of friction of the the entire measurement range up
can only be transmitted indirectly i.e. contact surfaces. For this reason to overload
by friction. This means that the interchangeable jaws or jaw inserts
frictional force between the specimen with various types of gripping • Very high effective measured value
ends and the jaws of the specimen surfaces (differing shape, surface resolution and measurement
grips must always be greater than structure, material etc.) are provided frequency in combination with
the test load. The gripping forces for many specimen grips. testControl
(perpendicular to the test load)
required for this are generated exter- Clamping Travel and Opening • General overload protection
nally (e.g. by pneumatic pressure) or Width through testXpert® II; mechanical
derived mechanically from the test protection also available for load
load (self-tightening specimen grips). Specimen grips with external gripp- cells with low nominal force
ing force generation have long
clamping travel and thus also a large • Automatic sensor identification
opening width, leaving a larger free system
area for convenient specimen in-
sertion, even with thick specimens,
and eliminating the need for ex-
changeable jaws for different speci-
men thicknesses.
34
4.6 Testing under • Various test fixtures or specimen Testing under Temperature
Physiological Conditions grips can be connected /attached Influence
to the internally located mounting
Test in Liquid Media studs - Zwick has a large range of Many materials change their me-
submersible specimen grips chanical properties quite significantly
In the field of biomaterials, research • Quick dismantling for easy according to the ambient tempera-
is carried out into the mechanical cleaning; disinfection also possible ture. For testing applications at
properties of both regenerative and in autoclave at up to 120 °C elevated or low temperatures Zwick
artificial materials. To reflect the • Optional temperature control unit supplies various versions for quasi-
physiological conditions of the body, for installation in temperature- static and servo-hydraulic testing
the mechanical test should be per- controlled bath: heat exchanger machines. The temperature cham-
formed in a temperature-controlled with separate heating circuit, heat- bers are also suitable for retrofitting
fluid bath. Stents made of Nitinol are ing power 2 kW, temperature existing machines and applications.
also tested in a temperature-con- range: Room temperature to 80 °C.
trolled medium as the material Temperature control on the speci-
displays different characteristics at men via sensor arms; includes
37 °C from those at room tempera- separate container for pre-condi-
ture. tioning specimen.
Fig. 1: Media container with temperature Fig. 2: Horizontal testing machine with fluid
control unit bath
35
7 Zwick Services Laboratory for Fatigue and Laboratory for Quasi-Static
Impact Testing Applications
Applications Test Laboratory
and Contract Testing • Determining S-N curves for fatigue • Tensile, compression, flexure and
strength measurement of bonds, torsion testing
In the last few years Zwick's applica- structures, and weld seams • Testing under temperature
tions laboratory has become compe- • Fatigue test investigations under (-40 °C to +200 °C)
tence-center of materals testing with multi-axial load • Testing in high temperature range
active scientific exchange. • Fatigue strength investigations (+200 °C to +900 °C)
under in-service loadings • Determining impact strength
Functions: - single and multi-stage testing • Hardness testing
• Demonstrations and pre-testing - testing under temperature • Melt index testing
• Performing and evaluating tests on (-60 °C to +1200 °C) • Component testing
customers’ behalf - connecting rod testing under • Viscosity testing
simulated engine conditions • Fracture mechanics testing
Services: - corrosive media on request
• Use of full Zwick portfolio • Determining cyclic material
• Design and adaptation of specific behavior (LCF)
testing devices • Determining fracture mechanical
• Documentation and interpretation characteristic values
of component failure • Performing tests under impact
• Access to expert knowledge of test force
highly experienced staff • Application of measuring methods
• Evaluation and documentation of to obtain the relevant mechanical
tests values (crack propagation, crack
• Fast testing service to international detection, local strains, tempera-
standards, works standards and ture sequence etc.) for specimens
special regulations and components
• Advice on products, testing
methods and test performance
Fig 1: Zwick fatigue and impact testing laboratory Fig 2: Zwick laboratory for quasi-static
applications
36
5.2 Support for Validation
User Requirements Performance Qualification
of Zwick Testing Systems Specification
checked PQ
Legal Requirements and
Technical Specifications Operational Qualification
Directives (Application Specifications) (OQ)
OQ
Very high demands are placed on
Design Specifications Installation Qualification
the quality and reliability of products
an
Ris Asse (Hardware & Software Design) (IQ)
d
37
➍ Operational Qualification
(OQ)
In the scope of Operational
Qualification the operation of the
plant or system is checked. The
inspection takes place on the basis
of suitable test cases, for which the
test items and corresponding
acceptance criteria are defined and
specified in advance.
➎ Performance Qualification
(PQ)
Performance Qualification takes
place following successful
performance of Operational
Qualification and involves checking
whether a plant or system also
actually achieves the defined
performance parameters under real
production conditions. These tests
are repeated at regular intervals.
Zwick Qualification Services Fig. 1: Zwick service technician implementing Qualification (IQ/OQ) at the customer’s
premises
Zwick supports its customers in the
DQ, IQ and OQ steps in the form of Performing Qualification The individual test items are
comprehensive and individual on-site performed and each IQ or OQ test
qualification documentation, and in subsequently signed by qualifier and
performing qualification on-site. For Experienced service technicians system owner.
PQ, Zwick provides assistance with carry out the qualification at the
suitable options for testing defined customer’s premises on the basis of The results of IQ and OQ are
performance parameters. the qualification documentation summarized in the IQ and OQ Plan
produced. and Report and all deviations found
Qualification Documentation during IQ and OQ are documented,
from Zwick assessed as critical or non-critical
and measures to eliminate them are
Documentation is individually evolved.
adapted and produced to suit the
equipment of the testing system.
Regulatory requirements are
observed during creation of the
documentation. All documents are
to be authorized in advance.
38
5.3 Service and Support Repair Software Upgrade/Update
SupportDesk If, despite careful servicing and An update gives you access to the
maintenance a fault develops in a ongoing development of testXpert®
For further advice or assistance, testing machine, an engineer from software and opens the door to an
such as technical or software the large Zwick Service Network expanded range of functions.
support, the Zwick SupportDesk is in team will be with you in the shortest Changes to testing standards are
many cases a better option than an possible time. Many spare parts can also incorporated into the latest
on-site visit. Our experienced staff be dispatched within 24 hours. versions.
will use their wide-ranging technical
knowledge to provide you with an Calibration Upgrading from an old DOS operat-
answer speedily and effectively. ing system to the latest Windows
Zwick's calibration service is ac- equivalent provides a secure, reliable
Worldwide Service credited by DKD1), UKAS2), COFRAC3) route to the new technology. Up-
and A2LA4) to DIN EN ISO/IEC grade from testXpert® to testXpert® II
Customer satisfaction has the 17025 for on-site calibration of and enjoy access to all the latest
highest priority at Zwick Roell A.G. materials testing machines. testXpert® developments, with their
Local service organizations in over many benefits for everyday use.
50 countries ensure optimum The reference measuring equipment
utilization and maximum availability of used is regularly recalibrated. De-
your testing systems. pending on the customer's require-
ments, either a works calibration
(Zwick calibration certificate), ISO
calibration (Zwick certificate with
documentation showing measuring
equipment supervision to ISO9001)
or DKD calibration (DKD certificate) is
performed.
39
Zwick Roell AG
August-Nagel-Str. 11
D-89079 Ulm
Phone +49 7305 10 - 0
Fax +49 7305 10 - 200
info@zwickroell.com
www.zwickroell.com
Indentec
Hardness Testing Machines Ltd.
www.indentec.com