EiE INSTRUMENTS TC-106 User manual
PRODUCT USER MANUAL : EIE_TT_DATM_PUM_00
Revision No.: EIE/TT/DATM/REV.00 Dtd. 03/07/2018
INSTRUMENT: DEEP ABRASION TESTING MACHINE
Page No.: 2 of 22
Organization’s ISO 9001:2015 Certificate
PRODUCT USER MANUAL : EIE_TT_DATM_PUM_00
Revision No.: EIE/TT/DATM/REV.00 Dtd. 03/07/2018
INSTRUMENT: DEEP ABRASION TESTING MACHINE
Page No.: 3 of 22
Forward
Dear valued customer,
We just want to take a moment out to thank you for your keen interest in our company products. We greatly
appreciate your business and the opportunity you provided us to assist you. You have joined a selected group
of customers who have switched to the technologically superior and quality enhanced laboratory testing
product.
Time has changed, so do the technology. Your purchase lists you on the cutting edge of 21st century technology.
The attached test report is an excellent way of expressing and maintaining your trust in EIE’s - superior quality
testing products. Our continued efforts and commitment is to provide you efficient sales after services, prompt
attention and highest level of customer satisfaction. If for any reasons, you have questions or comments, we are
delighted to hear from you. Call us on 0091-79-66040613 or send us email at kunal@eieinstruments.com. You can expect
us to respond to your email within 24 working hours.
Once again, thank you for your trust and kind patronage. We look forward to serve you better in future.
Yours sincerely,
EIE Instruments
PRODUCT USER MANUAL : EIE_TT_DATM_PUM_00
Revision No.: EIE/TT/DATM/REV.00 Dtd. 03/07/2018
INSTRUMENT: DEEP ABRASION TESTING MACHINE
Page No.: 4 of 22
Table of Contents
Organization’s ISO 9001:2015 Certificate...........................................................................................2
Forward............................................................................................................................................2
List of Figures....................................................................................................................................4
List of Table ......................................................................................................................................4
1. Introduction to Standard Methodology..................................................................................5
1.1 Necessity...........................................................................................................................................5
1.2 Principle ............................................................................................................................................5
1.2.1 Abrasive material...............................................................................................................................5
2. Introduction to EIE –Instrument/Apparatus...........................................................................7
2.1 Installation/Construction & Parts Details............................................................................................7
3. Experimental –Operation & Maintenance .............................................................................9
3.1 General Instructions...........................................................................................................................9
3.2 Delivery and Uncrating the instrument...............................................................................................9
3.3 How to make instrument ready for the use?.......................................................................................9
4. Standard Operating Procedure.............................................................................................10
4.1 Preparation of Test Specimen...........................................................................................................10
5. Expression of Results ...........................................................................................................15
6. Precautions to be observed-General ....................................................................................20
Warranty Certificate .......................................................................................................................21
List of Figures
Figure 1 White Aluminum Oxide..........................................................................................................................................6
Figure 2 Component Diagram ..............................................................................................................................................8
Figure 3 Control Panel .......................................................................................................................................................14
Figure 4 Measurement of specimen’s chord after operation test ......................................................................................14
Figure 5: Counter for setting the revolution.......................................................................................................................15
List of Table
Table 1 Grain Size requirement as per INDIAN STANDARD IS 11643 ....................................................................................6
Table 2 Technical Specification ............................................................................................................................................7
Table 3 Equivalent Values..................................................................................................................................................20
PRODUCT USER MANUAL : EIE_TT_DATM_PUM_00
Revision No.: EIE/TT/DATM/REV.00 Dtd. 03/07/2018
INSTRUMENT: DEEP ABRASION TESTING MACHINE
Page No.: 5 of 22
1. Introduction to Standard Methodology
Tiles are a thin slab, having a full cross-section, made from clays and/or other inorganic raw materials generally
used as a covering for floors and walls, usually shaped by extruding or dry-pressing at room temperature, but may
be formed by other processes, then dried and subsequently fired at temperatures sufficient to develop the
required properties. The tiles may be glazed (GL) or unglazed (UGL). They are incombustible and unaffected by
light. They are usually manufactured by extrusion, generally unglazed, and are classified in groups by different
properties and abrasion test as specified in the standards i.e. IS 13630(Part-12), standard test method for
determination of resistance to deep abrasive wear of unglazed ceramic tile by rotating disc. By taking this
concept, EIE offers an instrument i.e. DEEP ABRASION TESTING MACHINE
1.1 Necessity
Unglazed ceramic tiles used for floor coverings are evaluated for resistance to deep abrasion using this test
method. Abrasion is achieved by a rotating disc and a continuous flow of abrasive grit to the tile surface.
1.2 Principle
Determination of the abrasion resistance of unglazed ceramic tiles by measuring the length of the groove
produced in the proper surface by means of rotating disc under given conditions and with the use of abrasive
material.
1.2.1 Abrasive material
White fused aluminium oxide conforming to the grain size requirement of Grit No.80 of Table1 of IS: 11643.
PRODUCT USER MANUAL : EIE_TT_DATM_PUM_00
Revision No.: EIE/TT/DATM/REV.00 Dtd. 03/07/2018
INSTRUMENT: DEEP ABRASION TESTING MACHINE
Page No.: 6 of 22
Table 1 Grain Size requirement as per INDIAN STANDARD IS 11643
Figure 1 White Aluminum Oxide
PRODUCT USER MANUAL : EIE_TT_DATM_PUM_00
Revision No.: EIE/TT/DATM/REV.00 Dtd. 03/07/2018
INSTRUMENT: DEEP ABRASION TESTING MACHINE
Page No.: 7 of 22
2. Introduction to EIE –Instrument/Apparatus
2.1 Installation/Construction & Parts Details
It consists essentially of a rotating disc, a storage hopper with dispensing device for the abrasive material; a
test specimen support and a counterweight (see below figure of component diagram).
The disc is made of Fe 410-S steel as specified in IS: 2062, with a diameter of 200 ± 0.2 mm, and thickness at
the edge of 10 ± 0.1 mm, and with a rate of revolution of 75 rev/min.
The pressure with which test specimens are held against the steel disc is determined by calibrating the
apparatus against transfused silica.
The pressure is adjusted such that, after 150 revolutions a chord of 24 mm is produced. When the diameter
has worn to 199mm, the steel disc shall be replaced.
Diameter of steel disc
Thickness of steel disc
Material of steel disc
Speed of rotation of disc
Force applied on test specimen
Motor
Counter
Capacity of storage hopper
200 ± 0.2 mm
10 ± 0.1 mm
Stainless Steel
75 ± 5 rpm
Counter-weight
1/4 HP single-phase 230 volts AC.
3 digit pre-set type electronic counter with
memory back up and push button reset.
500g
Table 2 Technical Specification
PRODUCT USER MANUAL : EIE_TT_DATM_PUM_00
Revision No.: EIE/TT/DATM/REV.00 Dtd. 03/07/2018
INSTRUMENT: DEEP ABRASION TESTING MACHINE
Page No.: 8 of 22
Figure 2 Component Diagram
1. TEST SPECIMEN CLAMP
2. FIXING SCREW
3. TEST SPECIMEN
4. VALVE
5. STORAGE HOOPER FOR ABRASIVE MATERIAL
6. EVEN-FLOW FUNNEL
7. STEEL DISC
8. COUNTERWEIGHT
PRODUCT USER MANUAL : EIE_TT_DATM_PUM_00
Revision No.: EIE/TT/DATM/REV.00 Dtd. 03/07/2018
INSTRUMENT: DEEP ABRASION TESTING MACHINE
Page No.: 9 of 22
3. Experimental –Operation & Maintenance
3.1 General Instructions
The instructions for preparing the equipment assume that the user is aware of the contents of this document,
which lists the warranty conditions and important precautions.
3.2 Delivery and Uncrating the instrument
1. Inspect equipment and shipping crate immediately upon receipt. If any damage is apparent, immediately
discuss it with the delivery person and contact the transportation company immediately. Make notes of any
damages on the bill of landing.
2. Retain all shipping material for later inspection.
3. Check packing slip carefully and ensure all materials have been received as indicated in packing slip.
4. If Instrument is supplied in enclosed wooden case, Unpack the wooden case, locate and count the number
of accessories and main working unit. Remove packing strip from surroundings of the instrument and all its
accessories. Please inspect and note whether any part of the instrument is damaged or any accessory is
missing according to packing slip? If it is so, then immediately make note of it and report to the manufacturer.
5. Due to the vibration incurred during shipping and handling, it is possible that mechanical connection could
become loose. Inspect all connection to ensure that they are secure.
6. After visual inspection, if everything is found to be okay, transit the instrument to suitable safe place where
it is intended to install. Caution: Handle with care.
7. Recycle the packing material and wooden box. Do not throw it away for environment protection.
3.3 How to make instrument ready for the use?
A. Place the equipment on a plain, even and sturdy surface leaving approx. 4”-5” inch space away from the wall.
B. Do not use equipment set in a corrosive environment. A corrosive environment may lead to poor
performance and deterioration of unit.
C. Keep instrument away from draft, sunlight, water or near a place of equipment, which emits heat as well as
electromagnetic conduction emission.
D. Keep Standard Operating Procedure and Respective Standard ready to conduct the test.
PRODUCT USER MANUAL : EIE_TT_DATM_PUM_00
Revision No.: EIE/TT/DATM/REV.00 Dtd. 03/07/2018
INSTRUMENT: DEEP ABRASION TESTING MACHINE
Page No.: 10 of 22
4. Standard Operating Procedure
4.1 Preparation of Test Specimen
Test shall be carried out using whole tiles or test specimens of suitable dimensions. Before testing, small
specimens shall be fixed with an adhesive onto a larger background, avoiding joints.
1. Take a Fixture in which we have to place the specimen by using clamps.
2. Place the test specimen in the apparatus so that it is tangential against the rotating disc with fixture.
3. Fix the screw tightly.
4. We can place the sample vertically also (As per suitability).
PRODUCT USER MANUAL : EIE_TT_DATM_PUM_00
Revision No.: EIE/TT/DATM/REV.00 Dtd. 03/07/2018
INSTRUMENT: DEEP ABRASION TESTING MACHINE
Page No.: 11 of 22
5. Place fixture with fixed specimen sample on machine properly.
6. Adjust the horizontal fixing screw for supporting the specimen on the machine.
7. Tighten the upper supporting screws also.
8. Place the given default weight on pulley.
PRODUCT USER MANUAL : EIE_TT_DATM_PUM_00
Revision No.: EIE/TT/DATM/REV.00 Dtd. 03/07/2018
INSTRUMENT: DEEP ABRASION TESTING MACHINE
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9. Now, for adding abrasion material i.e. aluminum oxide in funnel, close the red valve tightly.
10. Add the abrasion material in funnel as per standard i.e. Ensure that the feed of abrasive material into the
grinding zone is uniform at a rate of at least 100gm/100 revolutions.
11. Open the round type red valve upto the mark.
12. Adjust the Nob type red valve (it is present below the round type red valve) in such way, we will get at least
100gm/100 revolutions.
PRODUCT USER MANUAL : EIE_TT_DATM_PUM_00
Revision No.: EIE/TT/DATM/REV.00 Dtd. 03/07/2018
INSTRUMENT: DEEP ABRASION TESTING MACHINE
Page No.: 13 of 22
13. Switch ON the mains supply, set the no. of counts in counter by using UP, SIDE, SET keys etc. (i.e. 150
Revolution approx. or as per suitability) and START the system.
14. Rotating disc will start to rotate with respect to the set value of count on the counter i.e. 150 revolutions.
15. Add extra weight one by one (only if require).
16. Observe the process on control panel upto completion of set revolution i.e. 150 revolutions.
PRODUCT USER MANUAL : EIE_TT_DATM_PUM_00
Revision No.: EIE/TT/DATM/REV.00 Dtd. 03/07/2018
INSTRUMENT: DEEP ABRASION TESTING MACHINE
Page No.: 14 of 22
After completion of the process operation, remove the extra weight and default weight, disassemble the fixture
clamp and remove the specimen for measurement.
NOTE: Remove the test specimen from the apparatus and measure the' chord length of the groove by means of
the measuring gauge to the nearest 0.5 mm. Test each specimen in at least two places at right angles on its proper
surface.
Figure 3 Control Panel
Figure 4 Measurement of specimen’s chord after operation test
If relief surfaces would interfere with the determination of the abrasion resistance, the projections may be
ground of but the results of the test will not be the same as for tiles having plane surfaces.
PRODUCT USER MANUAL : EIE_TT_DATM_PUM_00
Revision No.: EIE/TT/DATM/REV.00 Dtd. 03/07/2018
INSTRUMENT: DEEP ABRASION TESTING MACHINE
Page No.: 15 of 22
5. Expression of Results
The resistance of deep abrasion is expressed as the volume V of material removed, in cubic millimeters. This
is calculated from the chord length of the groove by means of the expression:
V =
Where,
d = diameter of the rotating disc, in mm;
h = thickness of the rotating disc, in mm;
α = angle (in degrees) subtended at the Centre of the rotating disc by the chord
l = length of the chord, in mm.
NOTE: A minimum of five test specimens shall be tested.
Procedure for setting the disc revolution
Turn on the mains supply of the machine.
The following will be displayed in the controller (As shown in figure 6).
Figure 5: Counter for setting the revolution
PRODUCT USER MANUAL : EIE_TT_DATM_PUM_00
Revision No.: EIE/TT/DATM/REV.00 Dtd. 03/07/2018
INSTRUMENT: DEEP ABRASION TESTING MACHINE
Page No.: 16 of 22
Press the set button in the counter.
Use the arrow key as shown in the figure to shift to the next digit of the count to be set.
TO SET
THE
COUNT
TO SHIFT TO THE
NEXT DIGIT OF THE COUNT
PRODUCT USER MANUAL : EIE_TT_DATM_PUM_00
Revision No.: EIE/TT/DATM/REV.00 Dtd. 03/07/2018
INSTRUMENT: DEEP ABRASION TESTING MACHINE
Page No.: 17 of 22
Now to increase or decrease the value of the count, use the arrow key as shown in the figure
TO INCREASE /DECREASE
THE VALUE OF COUNT
PRODUCT USER MANUAL : EIE_TT_DATM_PUM_00
Revision No.: EIE/TT/DATM/REV.00 Dtd. 03/07/2018
INSTRUMENT: DEEP ABRASION TESTING MACHINE
Page No.: 18 of 22
Once the required value of the count is set, press the enter button.
ENTER BUTTON TO ENTER THE REQUIRED COUNT
PRODUCT USER MANUAL : EIE_TT_DATM_PUM_00
Revision No.: EIE/TT/DATM/REV.00 Dtd. 03/07/2018
INSTRUMENT: DEEP ABRASION TESTING MACHINE
Page No.: 19 of 22
After setting the count and pressing the enter button the following will be displayed.
Now to start the rotation of the disc press the enter button once again.
PRODUCT USER MANUAL : EIE_TT_DATM_PUM_00
Revision No.: EIE/TT/DATM/REV.00 Dtd. 03/07/2018
INSTRUMENT: DEEP ABRASION TESTING MACHINE
Page No.: 20 of 22
Some equivalent values are given in Table below:
l
v
l
v
l
v
l
v
l
v
mm
mm3
mm
mm3
mm
mm3
mm
mm3
Mm
mm3
20.0
67.0
30.0
227
40.0
540
50.0
1062
60.0
1851
20.5
72.0
30.5
238
40.5
561
50.5
1094
60.5
1899
21.0
77.0
31.0
250
41.0
582
51.0
1128
61.0
1947
21.5
83.0
31.5
262
41.5
603
51.5
1162
61.5
1996
22.0
89.0
32.0
275
42.0
626
52.0
1196
62.0
2046
22.5
95.0
32.5
288
42.5
649
52.5
1232
62.5
2097
23.0
102.0
33.0
302
43.0
672
53.0
1268
63.0
2149
23.5
109.0
33.5
316
43.5
696
53.5
1305
63.5
2202
24.0
116.0
34.0
330
44.0
720
54.0
1342
64.0
2256
24.5
123.0
34.5
345
44.5
746
54.5
1380
64.5
2310
25.0
131.0
35.0
361
45.0
771
55.0
1419
65.0
2365
25.5
139.0
35.5
376
45.5
798
55.5
1459
65.5
2432
26.0
147.0
36.0
393
46.0
824
56.0
1499
66.0
2479
26.5
156.0
36.5
409
46.5
852
56.5
1541
66.5
2537
27.0
165.0
37.0
427
47.0
880
57.0
1583
67.0
2595
27.5
174.0
37.5
444
47.5
909
57.5
1625
67.5
2636
28.0
184.0
38.0
462
48.0
938
58.0
1669
68.0
2717
28.5
194.0
38.5
481
48.5
968
58.5
1713
68.5
2779
29.0
205.0
39.0
500
49.0
999
59.0
1758
69.0
2842
29.5
215.0
39.5
520
49.5
1030
59.5
1804
69.5
2906
Table 3 Equivalent Values
6. Precautions to be observed-General
A. While cleaning, take care that the small/sensitive parts which should not get damaged.
B. Keep the instrument tidy, clean and dry with mint cream. Before initiating the fresh day, use preferably clean
soft cloth. Brush up the unit body as to maintain its finishing.
C. When the machine is not in use, cover it properly.
D. Disassembly of this equipment is strictly limited to the qualified persons and licensed engineers.
E. In case of any difficulty, please do not try to repairs without consulting us, especially when the instrument is
under warranty period.
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