Universal Testing Machine ~ Ourengineeringlabs

Universal Testing Machine

Also Read

Description: The machine is hydraulically operated, vertical, floor mounted, designed for testing metals and other materials under tension, compression, bending/transverse loads.
The machine comprise of following main parts

loading frame
hydraulic pumping system
PC Based control system and application software
Accessories

1) Loading Frame:
The loading frame is robust and extremely rigid construction with high stiffness. It consists of a central cross head whose position is adjustable through a geared motor depending on the size of the test specimen. The lower table is carried by the piston of the hydraulic ram of suitable capacity positioned in the cast iron base of the machine. The upper cross head is carried by four steel columns fixed to the lower table. The machine have six pillars in total for stability and rigidly. Compression, transverse, bending, shear and hardness tests are carried out between the central cross head and lower table while the tension test is carried between the central and upper cross heads.
Sensing of load is through a strain gauge based transducer (both tension and compression type), while the movement of the lower table (ram stroke) is measured by displacement transducer.
Safety feature like over travel limit for central cross head. over travel limit for ram and over loading of the system are provided as standard with the machines.
2) Hydraulic pumping system:
Hydraulic power supplies are compact in design and are suitable for the supply of required flow and pressure for the movement of the actuator. It has an oil tank of adequate capacity, vane type pump powered by a three phase motor. All the electrical controls including the temperature controller are fixed on one side of the tank. It includes all the accessories like pressure line filter, return line filter, oil level, relief valve, pressure gauge and air cooled heat exchanger. Anti vibration mountings are provided as standard along with the HPS.
A suitable water cooled heat exchanger for keeping oil within working temperature range is provided as standard. The system is kept at a distance from the loading unit and connected through flexible pipes.

Broad specifications of the system are:
Flow of the pump	10 LPM
Motor capacity	5 H.P.
Capacity of the tank	100 liters
Operating pressure	200 Bars
Heat exchanger	4500 Kcal/hr

System will be supplied with necessary cable and fittings for the operation of the machine. Total machine operates on 440V AC. 3 Phase, 50Hz.
3) PC Based control system and application software: Control system provides the digital servo control, Ramp generation for the machine actuator, data acquisition etc. for the continuous operation of the system.
(a) Signal Conditioning and Controlling Unit
Servo controller basically consists of signal conditioning unit and controlling unit. Signal conditioning unit receives the output signal from the various transducers (Load cell/Pressure Transducers and LVDT) and amplifies and process that signal as per the requirement and transfer it to computer through connecting cables where it is accepted by the data acquisition system. The output from the signal conditioning unit for each transducers range from 0 - 5V Control is on either load/stress or displacement or strain basis. It consists of dedicated servo controller card that gives the desired processed signal through the P.I.D controller to the servo valve to operate in load or displacement mode. It also sends the signal to computer and accepts the command from the software to operate in desire manner. The parameters like rate of loading, safety limits for load can initially be programmed through the software. The facility is given to program the rate of loading from 0.5 kN/sec - 20kN/sec in load control and 0.01 mm/sec - 1.5 mm/sec in displacement control.
Specificton of controller:

Auto P.I.D operation with automatic pace rate control as programmed in the software
Closed loop update rate is 10 kHz
Control channels - Load/Displacement/Strain (Selectable)
Provision for two auxiliary channels for load cell
Fully computer controlled operation to start, stop and hold the machine
High speed data acquisition card with 100 kHz sampling rate
Load ranges -0 to 200 kN and 200kN to 1000kN
Displacement range - 0 to 250 mm
Load resolution - 0.1kN for 0 to 200 kN and 1 kN for 200kN to 1000kN
Displacement resolution - 0.01 mm
Strain resolution - 0.01%
System accuracy:
Load accuracy: 5. ±0.5% of the measured load from 1% to 100% of capacity of machine
Displacement accuracy: 0.5% of measured valve from 1- 250 mm
Strain accuracy: 5_ 0.1% of measured value of strain
Type of loading - Static (Ramp) in both load and displacement/strain control
Static ramp rate:
Load control mode - 0.5kN/sec to 20kN/sec
Displacement control mode - 0.01mm/sec to 1.5mm/sec
Strain control mode - 0.0025/sec to 0.025/sec
Environmental temperature - 10 ° C to 50°C
Relative Humidity - 10% to 70%
Supply Input - 220 to 240 V (AC), 50 Hz

(b) Dedicated computer for controlling and data acquisition System is provided with dedicated computer with built in data acquisition card. Broad specifications of the computer and data acquisition card are given below.
Computer:
Intel i5 processor, 320 GB HDD, 2GB RAM, DVD R/W drive, 17" TFT Screen, Laserjet Colored printer, UPS 500V A
Data acquisition card:
The PCI Bus advanced data acquisition card provides the following advanced features

32 bit PCI — bus
16— bit analog input resolution
Auto scanning channel selection up to 16 channels
Up to 100 KHz AID sampling rates
16 single ended analog input channels
Bipolar input signals
Programmable gain of xl, x2, x4, x8, x16
Input range: ±10V, ±5V, ±2 .5V , ±1.25V, ±0.625 V.
One 12 -bit monolithic multiplying analog output channel
16 digital output and 16 digital input channels
4 extended digital input and output channels on the 37 — pin connector
3 independent programmable 16 -bit down counters.
Three A/D trigger modes: Software trigger, programmable pacer trigger and external pulse trigger.
Pr -trigger control
Internal DC to DC converter for stable analog power source.

(C) Application Software:
Application software is the integral part of the system for precise controlling, operation and data acquisition, storage, processing, analysis and reporting. It provides flexibility to user to do statistical analysis of test results and report generation as per relevant standards such as ISO, ASTM, DIN etc.
Salient features:

Programmable rare of loading (Pace Rate) and other sample parameters
Inching (Rapid approach)/ Release operation
Independent taring of presetting of load facility for auto zeroing of deflection at preset load.
Facility to test parameter setting and creation of test methods/profiles up to 30.
Save and recall of test methods for accurate and repeatable testing
Auto release of system facility after sample failure
To see the post failure behavior of the specimen
Operator selectable measurement unit — English, Metric, SI etc.
Programmable limits for load, displacement and strain
Facility to hold machine load up to 24 hours with continuous pump running up to full machine capacity and restart the loading during the test.
Online display of numerical value of load, displacement and extensometer
Automatic scaling of graphs in real time plotting
o Load v/s Time
o Displacement v/s Time
o Load v/s Displacement
o Stress v/s Strain
o Load v/s Extensometer
o Extensometer v/s Time
Automatic display of breaking load at the end of the test
password protection transducer calibration facility with 10 calibration points per transaucer with piece wise linear fit between point for maximum accuracy
Real time clock for tracking date, time and runs
Facility to save and retrieve test data along with order information about the specimen such as age, specimen no. , size, dimensions etc. in user defined file/ directory.
Calculation of various parameters such as load and elongation at yield, peak load and displacement at break, yield stress, modulus of elasticity, ultimate tensile strength, proof stress, compressive strength etc.
Multi graph and zooming option for comparison
Facility to print the data and all the graphs
Advanced statistical analysis (such as mean, SD, Variance etc.) for processing of test results
Batch summary report with multi graph facility for comparison up to 30 specimen
Facility to export data to excel or PDF, detailed summary report.

4) Accessories:
a) Tensile test on round and TMT bar 6-40 mm Dia and Flat Section also.
b) Compressive test on Specimen Dia up to 300mm
c) Flexure/Bending with Table Length 1000 mm
d) Shear — Single and Double complete with Bushes for testing 6 mm -32 mm Dia Rods.
e) Brinell hardness test complete with Ball Indenter 2.5mm, 5.0mm and 10mm and Microscope.
f) Wire Rope attachment for use with 20mm dia wire ropes.
g) Bolt Test attachment for conducting test on bolt sizes from M-6 to M-30.
h) Roller Support System length up to 2000 mm Length for testing Leaf Springs.
Suitable for mechanical testing of following material