ROCKWELL HARDNESS TEST

The objective of the Rockwell Hardness Test is to evaluate and

quantify the hardness of a material by measuring its resistance
to permanent deformation under a controlled load and specific
indenter conditions. This test provides a standardized method
to assess a material's ability to withstand surface indentation,
which is directly related to its strength, durability, a0nd wear
resistance
Key Objectives:
1. Material Characterization:
To classify and compare materials based on their
hardness, aiding in the selection of materials for specific
engineering applications.
2. Quality Control:
To ensure that materials and components meet
predefined hardness specifications during manufacturing
processes.
3. Heat Treatment Evaluation:
To assess the effects of heat treatments (e.g., annealing,
quenching, tempering) on the hardness and mechanical
properties of metals and alloys.
4. Wear Resistance Prediction:
To predict a material's ability to resist abrasion,
deformation, and surface damage in various operating
conditions.
5. Standardization and Repeatability:
To provide a consistent, repeatable, and universally
recognized method for hardness testing.
By achieving these objectives, the Rockwell Hardness Test
plays a critical role in material science, manufacturing, and
quality assurance across industries.

Apparatus:
 1. Rockwell Hardness Testing Machine
2. Sample 1 M.B.I 5.8 (Nuts, bolt, and washers)
3. Sample 2 M.B.I 5.81 (Nuts, bolt, and washers)

Related Theory:
1.Hardness:
Hardness is a measure of a material's ability to resist
deformation, indentation, or scratching. It reflects the
strength and durability of a material's surface and is an
essential property in engineering, materials science, and
manufacturing.

2. Key Characteristics of Hardness:

a) Resistance to Indentation:
o Hardness is often assessed by applying a force using
an indenter and measuring the resulting deformation.
Materials with high hardness show minimal
indentation.
b) Resistance to Abrasion and Wear:
o Harder materials typically withstand wear and
surface damage better than softer materials.
c) Correlation with Other Mechanical Properties:
o While hardness is not the same as strength, it often
correlates with other properties like tensile strength
and toughness.

3.Types of Hardness:

1. Scratch Hardness:
o Measures a material's resistance to being scratched
by another material.
o Example: Mohs scale of hardness, where talc has
a value of 1 and diamond a value of 10.
2. Indentation Hardness:
o Measures resistance to deformation under a
concentrated load.
 o Methods: Rockwell, Brinell, Vickers, and Knoop
hardness tests.
3. Rebound or Dynamic Hardness:
o Measures the energy of a material's elastic recovery
after impact.
o Example: Shore hardness test for rubbers and
plastics.

Hardness Testing Methods:

a) Brinell Hardness Test (BHN):

o Uses a hard steel or carbide ball under a specific
load, measuring the diameter of the indentation.
b) Rockwell Hardness Test (HR):
o Measures the depth of penetration under a specified
load and scale, commonly used in metals and
plastics.
c) Vickers Hardness Test (VHN):
o Use a diamond-shaped indenter and is suitable for
very thin materials or coatings.
d) Knoop Hardness Test:
o Similar to Vickers, but uses an elongated diamond
indenter, ideal for thin films or micro-hardness
testing.
e) Mohs Scale:
o A qualitative measure based on the ability of a
material to scratch or be scratched by another.

4.Applications of Hardness:

a) Material Selection:
 o Helps choose materials for specific applications
based on wear resistance or surface strength
requirements.
b) Quality Control:
o Ensures materials meet the necessary hardness
specifications in production.
c) Heat Treatment Analysis:
o Evaluates the effects of processes like annealing,
quenching, and tempering on metal hardness.
d) Failure Analysis:
o Investigates the role of material hardness in wear,
fatigue, and deformation failures.
5.Factors Affecting Hardness
a) Material Composition:
o Alloys, crystalline structure, and bonding influence
hardness.
b) Heat Treatment:
o Processes like quenching or tempering can increase
or decrease hardness.

c) Temperature:
o Higher temperatures can reduce hardness by
softening the material.
d) Surface Condition:
o Polishing or surface defects can impact hardness test
results.

In summary, hardness is a critical material property that

reflects a material's ability to resist surface deformation and
wear. It is vital for determining the suitability of materials in
various applications, from industrial tools to consumer goods.

Standardization:
The Rockwell Hardness Test is governed by international
standards, such as:
 ASTM E18: Standard Test Methods for Rockwell Hardness
of Metallic Materials.
  ISO 6508: International standard for Rockwell hardness
testing.
Standards Referenced: Common standards include ASTM
A193, ASTM A325, ISO 898
These standards define:
 The types of indenters (e.g., diamond cone or steel ball).
 The test loads (minor and major loads specific to each
scale).
 Procedures for conducting the test, including specimen
preparation, test conditions, and result interpretation.
By following these standards, the Rockwell test provides
results that are:
 Comparable across different testing machines and
laboratories worldwide.
 Recognized universally for quality assurance and
certification purposes.

Repeatability:
The Rockwell test is designed to produce consistent
results when repeated under the same conditions.
Repeatability ensures that,
 The same sample tested multiple times under identical
conditions yields nearly identical hardness values.
 Different operators using the same machine will obtain
consistent results.

Importance of Standardization and Repeatability

 Inter-laboratory Comparisons: When testing is

performed in different locations, standardization ensures
results are directly comparable. This is crucial in industries
with global supply chains.
  Quality Assurance: Repeatable hardness
measurements validate the consistency and quality of
production materials and components.
 Certification and Compliance: Standardized tests
provide documented proof that materials meet industry or
customer specifications.
 Minimized Variability: By controlling test parameters
and adhering to standards, variability in results is
minimized, enhancing confidence in the measurements.

In summary, standardization and repeatability ensure that the

Rockwell Hardness Test is a reliable and widely accepted tool
for assessing material hardness, which is essential for industrial
processes, quality control, and compliance with global
standards.

ROCKWELL HARDNESS TESTING MACHINE:

Introduction:
The Rockwell Hardness Testing Machine is a widely used
instrument designed to assess the hardness of materials such
as metals and plastics. Hardness, a fundamental property of
materials, reflects their resistance to deformation or
indentation, which is crucial in evaluating their suitability for
various industrial and structural applications. The Rockwell test
is based on a simple and efficient principle: the depth of
penetration of an indenter into the material under a specified
load determines the hardness value. Introduced in 1919 by
Stanley P. Rockwell, this method revolutionized material
testing by offering a quick, repeatable, and reliable way to
measure hardness. The Rockwell system encompasses multiple
scales, each tailored for specific material types, enabling
precise measurement across a wide range of hardness levels.

Machine images:
Principle of Test & Apparatus: A hardness test is typically
performed by pressing a specifically dimensioned and loaded
object (indenter) into the surface of the material you are
testing. The hardness is determined by measuring the
depth of indenter penetration or by measuring the size
of the impression left by an indenter. Indenters are
selected based on the product to be tested. Usually, we use
diamond and 1/16’’inch dia. ball indenter in the lab for testing
products. Similarly, scales are also selected based on indenter
used. For diamond indenter, we use C- scale which is in black
color and for steel ball indenter, we use B- scale which is in red
color.

METHODOLOGY:
Preparation:
a) Select the Specimen: Ensure the material is
representative of the part being tested.The specimen
thickness should be at least 10 times the depth of the
expected indentation to avoid errors.
b) Surface Preparation: The test surface must be smooth,
clean, and free from contaminants, rust, or coatings that
could affect results.
c) Determine the Test Scale: Choose the appropriate
Rockwell scale based on material type, hardness range,
and test requirements. Example: HRC for hard materials
like steel, HRB for softer materials like aluminum.

Procedure:
a) Place the Specimen: Position the specimen on the testing
anvil to ensure stable and proper alignment under the
indenter.
b) Apply the Preliminary Load (Minor Load): Apply a minor
load (typically 10 kg) to seat the indenter and eliminate
surface irregularities. Zero the depth measurement gauge
to establish a reference point.
c) Apply the Major Load: Add the major load (e.g., 100 kg for
HRB or 150 kg for HRC) smoothly and hold it for a
specified dwell time, usually a few seconds.
 d) Remove the Major Load: After the dwell time, remove the
major load while maintaining the minor load.
e) Measure the Depth of Indentation: The machine
automatically measures the depth of the permanent
indentation left by the indenter.
Reading and Recording the Hardness Value
a) The Rockwell hardness value is displayed directly on the
machine's scale or digital readout.
b) Record the hardness value along with the scale used (e.g.,
HRC, HRB).
Verification
a) Repeat the Test:Conduct multiple tests on the same
specimen to ensure accuracy and consistency. Use an
average value if required.
b) Compare with Standards: Check the measured value
against the material or industry standards to ensure
compliance.
Key Points to Remember:
 Testing Temperature: Conduct the test at standard room
temperature to avoid deviations.
 Anvil Selection: Use the correct anvil for specimen shape
and size to provide stable support.
 Avoid Edge Effects: Keep the indentation at least 2.5 times
the diameter of the indenter away from specimen edges.
By following this procedure, the Rockwell Hardness Test
ensures reliable, repeatable, and accurate hardness
measurements
Depth of Indentation: From
that hardness value we will calculate 1 unit of Rockwell hardness
the penetration of the indenter from machine is equal to 0.002mm
that value: Hardness value = E – e
Where, E is a constant; 130 for steel indenter, 100 for diamond
indenter e is the value of penetration
Description of scales:
Sam Speci Face Type S Load (kg) Hard Mean Dep
ple men of c ness hardn th
Inde a Maj Min Numb ess of
nter l or or er Inde
e nt
Loa Loa
(m
d d m)
HR86B
0.08
1/16” HR90B
90 HR89.3 1
Bolt Head dia. 10 HR92B 3B
B
Sam Steel
Reduce ball HR83B
ple 1 d HR82.7 0.09
inden HR83B
M.B. B 4
dia/
I ter HR82B
unthrea
5.8. ded
1 1/16” HR98B
Nut 1 HR98.3 0.06
dia. HR98B
B 3
Steel B 90 10 HR99B
Nut 2 ball
HR91B
HR96B HR94.3 0.07
inden HR96B B 1
ter
HR37C
Washe HR32C HR35C 0.13
r1 Diam C 140 HR36C
ond 10 HR33C
cone
HR36C HR34.3 0.131
Washe 3C
r2 HR34C

Head
HR86B
1/16”
HR94B HR90B 0.08
dia.
Samp Bolt B 90 10 HR90B
Steel
le 2 Reduc ball HR87B
ed dia/ inden HR85B
M.B. HR86B HR86B 0.088
unthre ter
I aded
5.8. Nut 1 HR89B
2 HR91.6 0.077
1/16” HR92B
B
dia. HR94B
B 90 10
Steel HR85B
Nut 2 ball HR92B HR87.3 0.085
inden HR85B 3B
ter

HR30C
 HR31C HR30C 0.14
Washe C
140 HR29C
r1 Diam
ond 10
Washe cone HR22C
r2 HR22.7 0.154
HR21C
C
HR25C

Sample Hardness
Specimen Calculated Standard
value value
Bolt HR89.33B HR70–100B
Sample 1 Nut1 HR98.3B HR68-95B
M.B.I
5.8.1
Nut 2 HR94.3B HR68-95B
Washer 1 HR35C HR35-45C
Washer 2 HR34.33C HR35-45C
Bolt HR90B HR70–100B
Sample
Nut1 HR91.6B HR68-95B
2
M.B.I Nut 2 HR87.33B HR68-95B
5.8.2 Washer 1 HR30C HR35-45C
Washer 2 HR22.7C HR35-45C
ISO 898-1

Comments:
Tension Test on Bolts, Nuts, and Washers
Using a 500 kN Shimadzu Testing Machine:
The tension test on bolts, nuts, and washers evaluates the
tensile strength and performance of these fastener assemblies
under axial tensile loads. This test determines whether the
components meet the mechanical property requirements for
their intended application. Using a 500 kN Shimadzu
Universal Testing Machine (UTM) ensures precise and
reliable results.

Objective:
To measure the tensile strength, elongation, failure load, and
mode of failure of bolt-nut-washer assemblies under axial
tension using a 500 kN Shimadzu Testing Machine.

Equipment and Materials

1. Testing Machine: Shimadzu UTM with 500 kN capacity.
2. Specimens: Assembly of bolts, nuts, and washers of
specified grade, size, and material.
3. Gripping Fixtures: Appropriate fixtures to hold the
assembly securely.
4. Calipers or Micrometer: For pre-test measurements of
bolt dimensions.

Related Theory:
 Yield strength: Yield strength is the stress at which a
material exhibits a specified limiting deviation from the
proportionality of stress to strain. The deviation is
expressed in terms of strain, percent offset, total
extension under load, etc.
  Ultimate strength: The ultimate strength of a material
in tension, compression, or shear, respectively, is the
maximum tensile, compressive, or shear stress that the
material can sustain, calculated based on the ultimate
load and the original or unstrained dimensions.
 Elongation: Percent elongation is a measurement that
captures the amount a material will plastically and
elastically deform up to fracture. Percent elongation is
one way to measure and quantify the ductility of a
material.

 Reduction area: The reduction in cross-sectional area of

a tensile specimen at fracture. Percent reduction in area
is also a measure of ductility.
 Gauge length: The term 'gauge length' refers to the part
of a test specimen being measured for elongation during
a tensile test.
 Proof Load: The proof-load test consists of stressing the
product with a specified load that the product must
withstand without measurable permanent set.

500 kN Shimadzu Testing Machine:

The 500 kN Shimadzu Universal Testing Machine (UTM) is
a high-capacity device designed for testing the mechanical
properties of materials and components. It is widely used in
industries and laboratories to conduct tensile, compression,
bending, and shear tests on metals, plastics, composites, and
fasteners. With a capacity of up to 500 kN, it provides precise
and reliable results under various testing conditions. The
machine features advanced load and displacement sensors,
ensuring accurate data acquisition and control. Equipped with
user-friendly software, it allows automated test procedures and
comprehensive analysis. This versatile equipment is essential
for quality control, research, and material certification.
Machine images:

Test Setup and Procedure

 Specimen Preparation:
 Assemble the bolt, nut, and washers as per the test
requirement.
 First the threads of the bolt are removed according to the
specification of the standard A-606
 Ensure the assembly is clean and free of defects, such as
burrs or damage.

 Measurement of Dimensions:
  Measure and record the dimensions of the bolt (diameter,
thread length, total length) and washer thickness.

 Machine Setup:
 Ensure the Shimadzu UTM is calibrated and functioning
correctly.
 Attach suitable gripping fixtures designed for tensile
testing of fastener assemblies.
 Mounting the Specimen:
 Position the bolt-nut-washer assembly vertically between
the grips.
 Ensure the alignment of the assembly to prevent bending
or eccentric loading.
 Application of Load:
 Apply a minor preload to seat the assembly properly.
 Gradually apply tensile load at a controlled rate, as
specified by testing standards (e.g., ASTM F606 or ISO
898-1).
 Observation During Testing:
 Record the load and elongation data in real time.
 Monitor the assembly for signs of yielding, deformation, or
failure.
 Yield and Maximum Load:
 Identify the yield point from the load-elongation curve.
 Record the maximum load (ultimate tensile strength)
before failure.
 Failure Analysis:
 Continue applying load until the assembly fails.

Observe and document the mode of failure, such as:

 Bolt fracture (shank or thread failure).
 Nut stripping.
 Washer deformation or cracking.
Post-Test Measurements
 Elongation:
 Measure the final length of the bolt to calculate
elongation.
 Examine Components:
 Inspect the bolt, nut, and washer for deformation or
damage.
 Document Findings:
 Note whether failure occurred in the bolt threads, shank,
nut, or washer.

ASTM F606 / F606M – Standard Test

Methods for Fasteners: Mechanical Testing
 Scope: This standard covers the mechanical testing of
fasteners, including bolts, nuts, screws, and washers, with
specific focus on tensile strength, yield strength,
elongation, and reduction in area.
 Relevance: It provides guidelines for tensile testing,
including the testing procedures for bolt, nut, and washer
assemblies under tension.
 Specifies the testing conditions like load application rates,
specimen preparation, and acceptable tolerances for
measuring elongation and tensile strength.
Tensile Strength: The tensile strength of bolts and fasteners typically ranges between 500
MPa to 1,000 MPa (megapascals), depending on the material and grade. For example:
  Grade 5 bolts have a tensile strength of around 850 MPa.
 Grade 8 bolts can have a tensile strength of 1,000 MPa or higher

Elongation: Elongation varies between 6% to 20%:

 Grade 5 bolts generally exhibit 12% elongation at fracture.

 Grade 8 bolts show 10% elongation or lower.

Reduction in Area: Standard reduction in area values range from 20% to 40%, depending
on the grade and material properties.

2. ISO 898-1 – Mechanical Properties of Fasteners

Made of Carbon Steel and Alloy Steel
 Scope: ISO 898-1 specifies the mechanical properties of
fasteners such as bolts, screws, and nuts made of carbon
steel or alloy steel.
 Relevance: It covers the tensile testing procedures for
bolts and nuts, including test load requirements and
allowable deformation.
 Testing Conditions: Defines the conditions for the
tension test, including loading rates, testing machines,
and acceptable limits for elongation, yield, and tensile
strength.
 Tensile Strength:
o Grade 8.8 bolts (common steel fasteners) have a tensile strength range of 800
MPa to 1,000 MPa.
o Grade 10.9 bolts (higher-strength steel fasteners) have a tensile strength range
of 900 MPa to 1,100 MPa.
o Grade 12.9 bolts (high-alloy steel) have tensile strengths ranging from 1,100
MPa to 1,300 MPa.
 Yield Strength:
o Grade 8.8 bolts have a yield strength around 640 MPa.
o Grade 10.9 bolts have a yield strength of approximately 900 MPa.
o Grade 12.9 bolts exhibit yield strengths of 1,100 MPa or more.
 Elongation: The elongation values for bolts and nuts in ISO 898-1 typically range
from 8% to 20%:
o Grade 8.8 bolts: 12% elongation.
o Grade 10.9 bolts: 10% elongation.
 Reduction in Area: Standard reduction in area values range from 20% to 40%,
depending on the grade and material properties.
3. ISO 3506-1 – Stainless Steel Fasteners: Part 1 –
Bolts, Screws, and Studs
 Scope: This standard specifies the mechanical properties
of stainless steel fasteners, including bolts, nuts, and
washers.
 Relevance: It includes requirements for tensile testing of
stainless steel bolts and nuts, focusing on their tensile
strength and yield properties.
 Testing Conditions: Details specimen preparation, test
conditions, and methods for determining tensile strength,
yield strength, and elongation
Tensile Strength:
 A2-70 (stainless steel grade) fasteners: Tensile strength
of approximately 700 MPa to 800 MPa.
 A4-70 (another stainless-steel grade) fasteners: Tensile
strength of about 750 MPa to 950 MPa.
Yield Strength: The yield strength for stainless steel
fasteners like A2-70 and A4-70 is around 500 MPa to 600
MPa.
Elongation: Stainless steel fasteners typically exhibit
elongation values in the range of 30% to 40%, reflecting
higher ductility.

Importance of Standards
The above standards ensure that tension tests are conducted
under consistent and repeatable conditions, providing reliable
data for evaluating the performance of bolts, nuts, and washers
in various applications. They also ensure that fasteners meet
the mechanical property requirements needed for structural
integrity and safety in industries like automotive, construction,
and aerospace.
Calculations:
Key Observations
 Ensure alignment of the assembly during testing to
prevent bending forces.
 Note whether failure occurs at the bolt shank, threads, or
nut threads.
 For washers, observe if deformation or cracking influences
the test outcome.

Safety and Precautions:

1. Ensure proper alignment to avoid bending stress.
2. Use gripping fixtures designed for fasteners to prevent
slipping or damage.
3. Monitor the machine closely during loading to avoid
exceeding its capacity.
4. Wear safety equipment to protect against sudden failure
of the assembly.

Conclusion:
 The tension test on bolt-nut-washer assemblies using the 500
kN Shimadzu UTM provides a comprehensive understanding of
the mechanical performance of these components. It ensures
they meet the required standards for strength and reliability in
their application.

Observation and Calculations:

Properties SAMPLE 1 SAMPLE 2
M.B.I 5.81 M.B.I 5.82
Gauge length (mm) 23.5 23.3

Diameter (mm) 10.35 10.45

Area (mm)² 84.13 85.77

Rupture Diameter 8.35 7.35

(mm)

Rupture Area (mm)² 54.76 42.43

Yield load (N) -- --

Ultimate load (N) 53200 57000

 Rupture Load (N) 43200 43700

Yield strength (MPa) -- --

Ultimate strength 632.35 664.57

(MPa)

Nominal rupture 513.49 509.5

strength (MPa)

True Rupture Strength 788.9 1029.93

(MPa)

Gauge length After 28.5 27.5

Elongation (mm)

%age Elongation 21.3 18.03

%age Reduction in 34.9 50.5

Area

COMPARISON WITH ASTM STANDARDS:

Sr Properties sam Standard Experimental
. ple values values
no ISO 898-1

.
M.B.I -- --
Yield 5.81
1. strength M.B.I 660 MPa. --
5.82
Ultimate M.B.I 632.35MPa
tensile 5.81
2. strength M.B.I 800 - 1,000 MPa. 664.05 MPa
5.82

% M.B.I 21.83 %
Elongation 5.81 18-20%
3. M.B.I 18.03 %
5.82
4. % M.B.I 50.5%
Reduction 5.81 35 – 40
in area M.B.I 34.9%
5.82
ISO 898-1
Comments: