Zwick Z5 kN Testing Machine

Operating Manual

Created by Chris Crouch Page 1 of 13 14/11/2013

Machine Reference A653782 Machine Type BT1-FR005TN Machine Serial No. 168336 Drive controller S.N. 168333 500 N Load cell S.N. 07-3291 200 N Load cell S.N. 05-340 20 N Load Cell S.N. 05-6120 TestXpert software V11.02

Maximum Speed 650 mm/min Minimum Speed 0.1 mm/min Width 440 mm Length 1,000 mm Read Zwick manuals before using machine (see e copy on PC) Experiment with Zwick TestXpert simulation software located on main PC to explore machine and test functions Understand the type of testing to be carried out, Tensile / Compressive / flexural Ensure specimen tooling is available and compatible for the Zwick testing machine Know the desired crosshead speed for testing the specimen Know the expected maximum load value Know the expected crosshead movement value Know the specimen dimensions To start the Zwick Testing Machine Safety Always use safety glasses or safety Shield when testing any specimens

Zwick Drive Unit and Controller

Isolator Switch

Machine Crosshead

Zwick Z5 kN Testing Machine

Operating Manual

Created by Chris Crouch Page 2 of 13 14/11/2013

Connect Video Extensometer to controller and PC if required Add tooling to machine to carry out Test Turn on main isolator on right hand side of drive unit to power up control electronics Turn on computer with Zwick software User zwick

Password zwick Open machine software TestXpert Icon see below LHS

Go to File pull down menu (located top LHS screen) see fig above RHS Open test program or program series Fmaxzug.ZPV Tensile template Max Force Values Fmaxdru.ZPV Compressive template Max Values

Hysteresis.ZPV Hysteresis Template Me008.ZPV Metal testing Template

Select program and screen opens to selected Program and test Environment. See fig below LHS Check correct Test Environment by opening Machine Icon, ensure links correct for test. Fig below RHS

Zwick Z5 kN Testing Machine

Operating Manual

Created by Chris Crouch Page 3 of 13 14/11/2013

Check Program information Check main screen set up as above LHS Check Icons available for Save As, Save Raw Data, Save PDF Check report parameters under pull down File > Report Editor > DCU Standard Report Check under pull down screen File > Export Interfaces > PDF . and TRA files available then check file storage path. See figs below.

Use Save as to copy and rename program to “your folder” before amending any information At bottom of Screen the Load / Extension / Grip to grip [LE] SCREEN values are in RED Press Drive System control “ON “ to change SCREEN values to WHITE and allow machine control through software. If press drive system button “POS” control through UP or DOWN buttons of controller and SCREEN changes to GREEN DRIVE SYSTEM CONTROLS (Located RHS of Machine Frame)

Zwick Z5 kN Testing Machine

Operating Manual

Created by Chris Crouch Page 4 of 13 14/11/2013

Set up machine limits Mechanical limits Position upper and lower mechanical stop on crosshead scale to suit tooling Software limits use Use Machine Icon or pull down menu to select Machine Check and Set following Crosshead settings / Loadcell settings/ Extensometer settings /

Test Environment settings

Then Set Testing Parameters For Simple Max Force values Fmaxzug.ZPV (Tensile) & Fmaxdru.ZPV (Compression) Open icon “ 1 inputs” (see below LHS) Grip to Grip Separation Adjust gripper distance to starting position and set G to G value LE speed Set speed crosshead travels to G to G starting position Pre-Load Set any preload value (Test begun after reaching Pre-Load value) Pre-Load speed Set speed crosshead travels to Pre-Load value

Zwick Z5 kN Testing Machine

Operating Manual

Created by Chris Crouch Page 5 of 13 14/11/2013

Test speed Set test speed Force Shutdown Threshold Test is terminated when force decreases to value entered Force threshold for break detection Break detection is activated after force value reached Upper Force Limit Test is terminated once this Force value reached Max Extension Test is terminated once this Extension value reached Sensor arm Separation Removal of extensometer when reached limit of its travel Clamp specimen to top gripper Zero force value using “Force 0” Icon Clamp specimen to bottom gripper Test specimen using “Start” icon

Zwick Z5 kN Testing Machine

Operating Manual

Created by Chris Crouch Page 6 of 13 14/11/2013

To transfer data to Ascii format Highlight specimen tested along browser specimen number 1,2,3,4,5 File Menu > Export interfaces > Under Results and Test curve TICK to store data as .TRA file extension or Excel Got to Setting Select test specimen NAME and FILE data path to save data Select “Automatic Numbering” or “Request User Name” Press “EXPORT NOW” Convert data to Excel format for greater flexibility of data and graph generation Save TEST DATA under TestXpert as file with extension “.ZSE” and nominate folder to save data into To switch off machine and PC reverse start up procedure Shutdown PC and turn off Isolator on drive unit Test Programs Master test programs have WIZARD icon to set all parameters and save under own tittle Test programs have INPUT icon to set individual specimen and test data Test Environment Machine settings - loadcell type, extensometer, maximum & minimum

Values. Call up template already loaded or define own environment. Set up Tensile Tooling Do not tighten clamping nut to Tensile tooling top and bottom Add Steel parallel to tool jaws Align parallel to machine or video extensometer and lightly clamp Move crosshead to Preload parallel up to value below max loadcell e.g. 150 N Clamp tooling nut to loadcell and base Set up Compressive Tooling Add compressive tooling to top and bottom fixing Slowly bring platens together, but ensure gap to suit dial calipers, Use Internal Dial Calipers from Zwick tooling draw to measure platen gauge length and add to software Gauge Length LE value. To set up 2 axis on Graphs Goto Curves > New > New Y Axis > select Y axis channel from pull down menu Goto attributes and change colour Y axis 2 > Auto scaling and Colour graph attributes

Zwick Z5 kN Testing Machine

Operating Manual

Created by Chris Crouch Page 7 of 13 14/11/2013

To export curve data from one zs2 into another zs2

1. open up the series zs2 file from which you want to export the data 2. select the first test to export and right click and select “test curves export”

3. select New and select Test curves (testXpert)

4. click OK 5. change the path/filename if you require or leave as according to program, I will change my export

this example to the desktop and call it test

Zwick Z5 kN Testing Machine

Operating Manual

Created by Chris Crouch Page 8 of 13 14/11/2013

6. Click Next 7. change the name and commentary if you require then Finalise 8. highlight the export you created and click EXPORT

9. This should create the file in the path selected 10. Click OK, then select the next test right click and export this test (note you only have to select

“export specimen” To get these tests into your other series:

1. open up the other series and select the next available position on the series

Zwick Z5 kN Testing Machine

Operating Manual

Created by Chris Crouch Page 9 of 13 14/11/2013

2. right click and select import specimen 3. choose the specimen to import

4. then select open 5. repeat for other tests

Zwick Z5 kN Testing Machine

Operating Manual

Created by Chris Crouch Page 10 of 13 14/11/2013

VIDEO EXTENSOMETER SET UP Video Extensometer TC-EXVIDEO.002 from Messphysik S/W V5.9.8.0 Model Minton MTV-13WIC S/N G52409846 LENS Focal Length 50 MM Max field of View 100 mm When using extensometer Connect video arm to front of machine Add camera to arm and connections to PC [Power pin to bottom board, Video pin to LHS connection] Connect RS232 cable between Machine PC and Video PC Set Zwick software - Machine – Video extensometer linked to extensometer Align Camera and arm to right angle position to specimen Adjust grips to right angle using tooling and tighten in position Add small level to top of camera to ensure alignment Add sample to grips Turn on back light to illuminate sample, may need white background or additional desk lamp to aid illumination Turn on Video Extensometer PC Ensure dongle at back of PC and RS232 interface cable connecting Tester PC to Video PC User STUDENT Password MEDM Open Video EYE Icon File menu Load Test Use Screen on monitor to focus camera to specimen Adjust aperture (back lens adjustment) to get correct lighting for sample Adjust focus (front lens adjustment) to get focused sample Filters for X2 and X4 definition available Camera may need to be moved along arm for better focus, Note field of view (FOV) will be affected Add markers or dot to specimen for use as gauge length position. [Permanent marker dot or line] Change specimen to calibrated gauge from video box Calibrate camera using black and white marks and there known distance apart Set specimen viewing window and three line grayscale window to calibrated gauge Press Calibrate button it automatically picks up marks and call up mark distance Transverse alignment and axial alignment can be tracked together and data stored [need 4 markers] Replace gauge with specimen

Zwick Z5 kN Testing Machine

Operating Manual

Created by Chris Crouch Page 11 of 13 14/11/2013

Align thick blue line to slice through image to show grayscale values Align red line to dark colours Set background settings white on black or black on white Press start key to identify gauge length marks and give distance between marks (ensure reading stable and record value) Press stop Go to Zwick PC Ensure bottom right hand side field shows specimen data (thickness, width gauge length) and enter gauge length from value recorded Press start test Window appears to check marks have been identified on Video PC, Press OK Test data shown on Zwick PC To store image or data from Video PC Create file name and directory to store images – Use DRIVE E to store data as large capacity and if kept in C drive slows programs. Start key pressed to start recording data Start test using Zwick PC start key Data storage to file path Shared drive E:/data Data processing – Post processing – uses Messphys software only User Defined – Choose file name – etc Select start or stop criteria as required

-> to configure Video.. Button NEW IMAGE SERIES

Zwick Z5 kN Testing Machine

Operating Manual

Created by Chris Crouch Page 12 of 13 14/11/2013

2.Start recordeing at menu 3. Start test 4. after test you can load the image-series and run it 5. to switch back to live measurement, klick on live

Zwick Z5 kN Testing Machine

Operating Manual

Created by Chris Crouch Page 13 of 13 14/11/2013

New image series saves images from test at required time rate Save in E drive Data transferred to zwick machine PC shared Drive D:/ [if links connected] Download data to network Goto start Run \\Carnot2\student\”username” Etc Turn off procedure is reverse to start up Shutdown Video PC Remove camera and store in case Remove arm and turn off backlight Shutdown Zwick machine PC Turn off Isolator on Drive Unit To enable Hysteresis Testing Machine set to Strain control Step 1 - strain control set value 1 Set value 2 Repeat step 1 by [10] times Set up steps before Save program e.g. Trina Problems As specimen expanded 300/400% dot marks become elongated and loose focus and definition, once camera can pick up marks will stop test and recording Deb sample, Marks on arm and pillar for height and distance (1 mtr) No filters used and white background Data stored under postgrad/Debbie Strain control can not be achieved through video extensometer unless add interface card and cables