Laboratory Manual

For

Universal Testing Machine

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 OPERATING INSTRUCTIONS FOR UNIVERSAL

TESTING MACHINE

APPLICATION:

Universal Testing Machine is designed for testing metals

and other materials under tension, compression,

bending, transverse, and shear loads.

PRINCIPLE OF OPERATION:

Operation of the machine is by hydraulic transmission of

the load from the test specimen to separately housed

load indicator.

Load is applied by a hydrostatically lubricated ram.

Main cylinder pressure is transmitted to the digital load

indicator housed in a pumping unit which then send

data to Data acquisition system for taking data on

computer (in case of Computerized Universal Testing

Machine). The load transmitted to the cylinder from the

machine consists of Straining Unit and Control Panel.

Hydraulic Circuit Diagram

STRAINING UNIT:
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This consists of hydraulic cylinder, motor driven chain

and sprocket drive and a table coupled with the ram of

the hydraulic cylinder, mounted on to a robust base.

The cylinder and the ram are individually lapped to

eliminate friction. The upper cross head is rigidly fixed

to the table by two straight columns.

The lower cross-head is connected to two screwed

columns which are driven by a motor. Axial loading of

the ram is ensured by relieving the cylinder and ram of

any possible side loading by the provision of ball seating.

An elongation scale, with a minimum graduation of

1mm, is provided to measure the deformation of the

specimen.

Tension test is conducted by gripping the test specimen

between the upper and lower cross-heads and other tests

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are conducted between the lower cross head and the

table.

The lower cross head can be raised or lowered rapidly by

operating the screwed columns, thus facilitating ease of

fixing of the test specimen.

Please note: The machine supplied with compression

platens for compression test, tension grips, jars for 1 set,

bending attachment for 1 set.

Load verification of the testing machine meets the

requirements of IS 1828-1975. Margin of error is ± 1%

over 1/5th of the adjusted measuring range.

The machine consists of two units, viz.

the loading unit is A

and the Control panel is B.

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NOTE:

• The jaws should be always released slowly.

• The upper and lower jaws are non-interchangeable.

The Compression platens viz. upper and lower are

provided for conducting compression test. The lower

compression plate is to be kept on the lower table in the

location hole provided and the upper compression plate

is to be clamped to the bottom of the lower crosshead.

For clamping this plate, take the jaw in the lower cross

head to their bottom-most position-keep the top plate on

the top of lower crosshead, place in such a position that

its protected portion fits correctly in the chuck slot,

resulting in correct position of control hole. Now insert

the clamp stud from the bottom through the hole of the

lower plate. The clamp stud will come out from the

central hole of the lower plate. Now screw the upper

compression plate to the clamp stud and tighten it

against the lower plate by the nut from above.

head is used from compression, bend, shear and

hardness tests, and the space between the lower and

upper cross heads is used for tension test. In any test,

the up and down motion of the lower table and upper

cross head assembly performs the loading action. The

mechanical up and down motion of the lower cross head

is provided for rapid initial space adjustment depending

on the length or height of the tension and compression

test specimen respectively.

Bending table, bending rollers and bending pane are

provided as an attachment for carrying out bend test.

An elongation scale is kept sliding on the scale rod which

is fixed between the lower table and the upper cross

head. The elongation indicating pointer is fixed to the

lower cross head. The scale can slide on the rod when

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the screw as its back is loosened and can be set to

indicate zero, before staring the loading on the specimen.

PUMPING UNIT:

Digital pumping unit is an elegant console wired for 220

V/440V, 50Hz power supply. Two plungers with

reciprocating motion operate to pump oil. The plungers

are operated by cam activated by motor. An oil reservoir

has a total cap of 15 ltr (approx) and is sent with a full

charge of multigrade oil of grade 20/40. A transparent

tube oil level indicator is provided on the tank. A load

indicator of Four Digital LED display if fitted on the panel

with facility of overload cut off. The load indicator is

calibrated by certified proving ring. A pressure release

valve is provided to start loading when open, the oil will

return to the pump even when pump are pumping. A

slow fast knob, a flow adjustment valve is provided to

adjust rate of flow. A clock wire rotation increased flow

and thereby rate of loading and anti-clockwise, position

power off switch is provided to indicate that power has

gone into the unit. The loading unit assembly is

connected to the console with the help of a high pressure

pipe.

Make the foundation of the machine as per the hole

provided in the machine and see there is a space to sit

for a person in case of any servicing, as there should be

sufficient space in between the loading unit and the

pumping unit.

Connect console to 220V/440V 50Hz AC supply. The red

indicator lamp glows showing the console has received

power supply.

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Procedure:-

1. Switch on the digital indicator.

2. Press the zero and the peak button to enter the peak

hold mode.

3. Close the release valve.

4. Place the specimen i.e. compression/ tension/

bending as per the instruction mentioned above.

5. Switch on the machine pump to start apply load on

the specimen.

6. Adjust the slow/fast knob for proper rate of loading.

7. Peak value is stored in the memory as soon as the

specimen is broken/ crushed.

8. Switch off the machine and release the pressure

with the help of release valve.

9. Allow the piston to come down.

10. Clean the platens.

11. Reset the peak button to bring the digital back to

zero.

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MAINTENANCE:

1. The machine should always be kept clean.

2. The platens and unpainted parts should be greased

when not in use to prevent rusting.

3. The oil level in the pump should be maintained

between the oil indication levels.

4. In no case the pump should be operated when there is

no oil in the pump or the oil level is below the lower

mark.

5. Hydraulic oil Servo System 526 of Indian oil

Corporation is filled in the machine. This oil or any

equivalent oil should be used only.

• When oil starts leaking from the jack cylinder

piston, the seal should be replaced.

• The oil in the system should be changed half yearly

as a normal practice but this period can be increased

and decreased according to the use of the machine.

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• Over tightening the pressure release valve should be

avoided. It should be kept a couple of turn unscrewed

when not being used.

• Care should be taken not to take out the ram more

than 250mm (maximum limit).

• The machine should never be over loaded beyond its

capacity.

• Due to constant R & D, specifications and features

are subject to change without any notice.

• If, the machine runs on generating set, there is no

guarantee for microprocessor based digital indicator. It is

advised, to keep load voltage stabilizer when running on

such a system.

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