zwick z50 kn testing machine operating manual

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Created by Chris Crouch of 20

Zwick Z50 kN Testing Machine Operating Manual

Machine Reference A701306 Machine Type BT1-FB050TN Drive Controller S. N 177595 / 2007 50 kN Load Cell S.N. 07-3803 500 N Load cell S.N. 07-3291 5 kN Load Cell S.N. 07-4878 Clip on Extensometer S.N. 815139 Software TestXpert 2 (All in suite Educational software) V 2.1 Maximum Speed 180 mm/min Minimum Speed 0.001 mm/min Width 440 mm Length 1,375 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 Shield when testing any specimens

Zwick Drive Unit and Controller

Isolator Switch at rear

Machine Crosshead

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Connect Clip ON Extensometer to controller if required then Add Tooling to Machine Turn on main controller isolator switch at rear of drive unit to power up control electronics While waiting for self test start up routine Turn on computer Enter User Administrator

Password BLANK Open Machine Software Icon TestXpert II see fig below LHS

Go to File pull down menu (located top RHS) Open test program or program series Master Tensile template

Master Compressive template or Look up testing type Metal or Plastic or Test Specification (ASTM) from list of programs Screen opens to selected Test Environment and Program Confirm correct Test Environment by opening Machine Icon [bottom LHS icon] Check links connected correctly see fig below RHS adjust if required

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Check Program info see fig below RHS Check Series Layout, Graph, and Wizard Tabs to ensure set as required 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 file 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 the bottom of the screen the Load / Extension / Gauge length values are in RED Press Drive System Control ON button to change SCREEN values to WHITE and allow machine control through the software. If press Drive System Control button POS [position], Machine control is through UP or DOWN buttons and the SCREEN changes to GREEN DRIVE SYSTEM CONTROLS (located RHS of Machine Frame)

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Set up Machine limits Mechanical limits Position Upper and Lower Stops on crosshead scale to suit tooling Software limits use Machine Icon or pull down menu to select Machine Check and Set following Crosshead settings / Loadcell settings/ Extensometer settings /

Test Environment settings

Set Testing Parameters Open “Wizard” Tab and ensure expanded list shown (see fig 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 above starting position Pre-Load (Fig above RHS) Set any preload value (Test begun after reaching Pre-Load value) Pre-Load speed Set speed crosshead travels to Pre-Load value

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Specimen data selection screen shown above LHS with choice of specimen shape RHS

Specimen Test data screen shown above LHS with End of Test screen on RHS

Results data selection screen shown above LHS with choice of Results for Calculation RHS

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E Modulus data screen shown above LHS with Yield Point screen on RHS

Break Investigation data screen shown above LHS with Extensometer screen on RHS

Actions after Test data screen shown above LHS with Test Data Memory screen on RHS

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Parameters for the Report data screen shown above LHS with Report preview screen on RHS Testing a Specimen Once the program has been chosen and parameters for test selected and program saved to folder, Use Start Position Icon to set crosshead with tooling into its starting position. Load specimen into bottom grips first and clamp grip. Use Force 0 Icon to zero force Align Specimen in top grip ensuring straight and parallel before clamping If using Video Camera Check alignment using video screen Use Start Icon to begin testing, data will appear in graph and on video until finished New specimen created (specimen 2) on specimen tree top LHS browser, to view data of finished test Specimen 1 must be highlighted then use Save PDF and Save Raw Data Icons to save data to folder.

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The table lists values for all specimens tested, Highlight individual specimen to highlight all values. The statistical table lists the Mean value, Standard Deviation and Coefficient of Variation. Can select to ignore data by Invalidate data line which invalidated Data from statistic analysis X = average value of specimen series S = standard Deviation of specimen series γ = Coefficient of data Variation When change parameter can re-evaluate to recalculate by selecting Evaluate Icon or select specimen in browser and right click to see menu options The individual samples can be seen on Graph Tab with blue lines indicating modulus line and Ultimate Stress value etc. 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 Save TEST DATA under TestXpert as file with extension “.ZSE” and nominate folder to save data to Raw Data files saved as .TRA files need to opened in Excel and then convert to columns. Select column A to highlight all data, then select data from pull down, then convert text to Columns, select delimiter value as semi colon then finish and data arranged in columns To switch off machine and PC reverse start up procedure Shutdown PC and turn off Isolator on drive unit Set up Tensile Tooling for first time Add grips to top and bottom fittings Do not tighten clamping nut to Tensile tooling Add flat Steel plate to act as a parallel between two tool jaws or Align specimen parallel to machine or video extensometer and lightly clamp Move crosshead using Drive System Controls to Preload value below max loadcell e.g. 150 N Clamp tooling nut to grips at top (loadcell) and grip at base Set up Compressive Tooling Add compressive tooling to top and bottom fixing Set crosshead speed very slow to avoid damage Slowly bring platens together, Ensure force applied BELOW MAX LOADCELL CAPACITY e.g. 300 N Top and Bottom platens now flat and parallel, Tighten up clamping nut. As remove load from platens, when get to Zero force reset grip to grip distance LE to Zero.

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EXTENSOMETER SET UP Ensure correct rollers used for gripping flat or round sample, change if required. Determine gauge Length required and set knife edge configuration. Ensure pin pushed into locating hole to lock extensometer into correct gauge length Check distance gauge length using vernier callipers

Go to machine mode then Extensometer to bring up menu. See fig above RHS Enter correct Gauge Length value and holding Extensometer Arrest Knob inside hole, click LO SET Ensure Permissible deviation set to 0.2 mm Check mark Safety area Monitor, see fig above RHS Minimum distance set to 8 mm can be reduced if necessary No to Gauge Length correction factor Only needed for video or non contact extensometers Only use change over from extensometer to crosshead for Brittle Materials Strain channel [dl] displays gauge Length value, Standard Travel displays data from extensometer Grip to Grip channel displays distance between tooling faces (40.8) Nominal Strain channel displays G to G increment data from crosshead (0.8) Check crosshead software limits are set to avoid damaging Extensometer Set up specimen within grips Under Start Menu Set speed value Accept Gauge Length Value Accept length correction Modulus points need to guessed at until first sample tested and then can be reset and re-evaluate data to ensure in elastic region of sample Check value for 0.2% Proof Strain appears before remove extensometer window appears adjust to suit (1% Strain) For help at any time Highlight line on screen and press F1 help window appears

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Graphical Sequence testing Open Program file Graphical Sequence Editor and go to Test Sequence Tab. See below LHS

Select Operation items from LHS menu and double click mouse, position mouse on rectangle and right click to drop operation inside. Rectangle highlighted and bottom of screen shows operation menu, this can be expanded to view clearly. Enter parameters needed and select next block until tree complete. Tree can be Extended or decreased by right click mouse and opening Configure Sequence Editor Add lines between each block, Test start ACTION ALREADY SET UP e.g Ramp Block then add parameters 2 N @ 10 mm/min Then drag Wave block over for cycling add parameters Strain set to 10 mm @ 10 mm/min

Strain set to 0 mm @ 10 mm/min No of cycles 3 Accept

Cyclic Testing Program

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ADVANCED LEVEL To use PDF files and save PDF data the PC printer has to be set up with Printer settings of : Apple Color – LW 12/660 PS or Apple Laserwriter 12/640 PS To add Icons to Program Go to Icon area and right click mouse see fig below LHS and open Icon window fig RHS

Select NEW Icon and select DIFFERENT ICON to view Icons available, choose Icon, Enter description of Icon function (Save As)

Select Action from Standard Action RHS pull down menu lists standard actions. See fig LHS above ZIMT Script Select Edit and window appears, write action (export data as pdf file) then compile and run to verify program works. See fig above RHS Dialog Open ?

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Create as many icon and macro functions as required. Set up Report format Go to File pull down menu and select Report Editor, this opens standard report menu see fig below

Highlight logo and select settings, new window opens, select picture and find required logo in PC directory Set height of logo to 2.5 or required setting Go to Border and select NEW, a new window opens scroll down to TEXT or required field and OK Write desired TEXT and set font to 16, select OK and move text DOWN below logo. See fig below LHS

Select Position and set X axis to left flush and Y axis to Middle. See fig above RHS Select Date and choose position on report View changes by selecting Preview and amend to suit

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Open Border to amend graph data see fig below LHS

Select settings and configure channels and units for graph axis. Go to expanded window, then Attributes to select line thickness to 0.4 mm. See fig above RHS Go to Preview to view all settings Then amend report Name to “DCU Standard Report” To ensure data saved in correct format, > Open file pull down menu and select Export Interfaces. See fig below LHS

View created pathways by highlighting and using Edit to see settings For PDF Ensure report DCU Std Report, Export files has correct directory etc, Postscript has Apple printer, Moment in time and Name are optional. See fig above LHS For Raw Data Files Create New pathway, Select Test Curves ASCII and select file export directory, Select Next to choose exported parameters and select Date/Clock Time, Select Next to choose Channels to be exported and units for each channel. See fig above RHS Select Next for Moment in time and Name are optional.

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To Amend Screen layout Set mouse in any part of screen and right click to bring up menu. See fig below LHS Then can Configure Graph (axis and units) Activate cross wires and place pointer anywhere on slope to view individual X and Y values Select Field contents allows choice of different or additional information viewed

Edit current Layout allows new menu to access whole page and amend. See fig above RHS To set up Video screen, See fig above Click cursor in area to be edited, Select Split Screen, Rotate fields to orientation needed, select Select Contents, scroll until find Video Recording and click OK, then Click OK to save. Edit Layouts opens into new menu and allows for new tabs to be added or deleted. Then edit settings by tick, auto record to set start and stop events [Start After removal extensometer and before necking – at Max load value- 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”

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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

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

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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

2. right click and select import specimen 3. choose the specimen to import 4. then select open 5. repeat for other tests

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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 To see the value of the extensometer on display screen :

1. from the configuration menu select channels 2. select new channel

3. select the following

4. Finalise 5. then close the dialog 6. click on the machine button and then ensure you are in expanded mode as below:

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7. Note I have a different extensometer connected here called macro yours will have a

different name. 8. connected your extensometer to the new channel as below:

then ok the dialog 9. finally right click on the status bar i.e. where the force etc at the bottom is displayed and

select configure running display.

10. then under display during test send the ext-abs over to the left side.

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11. set the units to either mm or um. Then ok the dialog Set up Extensometer to capture additional data Under Machine Icon and select Controller display Set Data transmission rate to 500 Hz Rate data saved to controller Also for loadcell Integration time 100 ms (range 2 – 500 ms) time between data capture to drive controller But for Extensometer and Crosshead Integration set to 2. Integration time for test data filtering (in a grid 2 ms) Save all updates Change look of Main screen [Series Layout] Click mouse in region to edit, right click for Configure / edit menu screen and amend data to suit, Change Type No., Part No. To any value or parameter (e.g. temp) Under Wizard and Specimen Data Cross section Factor usually set to 1 Only varies if testing sandwich block of three bonded parts and grips set for moving middle section so CSA would be doubled Negative Cross sectional factor set to 0 only used if cut out in sample and allows software to calculate sample CSA for stress values. Under Test Select results desired YS, UTS, modulus etc [Modulus Metals use regression/ Plastics use Seacant] Test curve export into new document or series data New – test curve export – send to folder (chris) Next – export specification Then new test series Import specimen data Arrow on data number If need to offset graph as two curves fall on top of each other Right click mouse on highlighted curve Configuration Upper limit Export Curve Export offset 10 = 1% distance apart 0r 100 = 10 % apart Right click results Configuration Legend configuration to graph

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Specimen data Left click twice Rename User Administrations guidelines If required Highlight tabs and set groups which part of software each can view Options – user management – user groups – new – set up limits User Groups>> Admin>> Master / Menu / Context / Standard A / Other PG>> Standard Action / Menu Tester Limited Menu>> Others / Std Actions / >>Help (1,2,3) >>Option (1,2,3,6) >>Spec Management (2,5) >>Machine (1,3-8) >>File (1,7,10) >>Menu (1,2,3,5,6) Tester No Menu >>Std Action √ >>Others √

zwick z50 kn testing machine operating manual

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