Universal Testing Machine (UTM) is an important quality control machine that is required for testing the tensile strength, compressive strength, bending strength, and so on of materials. Since these machines are required to work continuously and are involved in repetitive movements and measurement-based operations, it is expected that, over time, their performance may vary.
Therefore, regular maintenance of these machines is necessary to ensure accurate and precise results. This is important in quality control and manufacturing industries. Otherwise, errors in testing may lead to incorrect quality decisions and material failures. In this article, we will understand when a Universal Testing Machine needs to be maintained, the procedure involved in maintaining these machines, and why these machines are required to be maintained.
When Universal Testing Machine Needs Maintenance
A Universal Testing Machine requires maintenance in cases where there are inaccuracies in the testing, movements, or mechanical performance. Prolonged use of the machine is the most common scenario. During tests, there is wear on the grips, load cell, moving screw, and crosshead. This can cause a reduction in the smoothness of the machine over time.
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If a UTM machine is giving different readings for the same test sample, then there is a problem. The machine should also be maintained in cases where there has been a change of location. If the machine has been shifted from one location to another, then there is a possibility of changes in the machine's performance.
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Universal testing machine should also be calibrated when there has been a repair of some of the major parts of the machine. The parts that should be checked regularly include the load cell, grips, motor, and controller.
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If the machine is located in a dusty environment, then it should be calibrated regularly. Most quality control labs maintain the machine every 6 months. The machine should also be maintained yearly.
UTM Machine Maintenance Schedule
|
Frequency |
Maintenance Task |
Key Focus |
|
Daily |
Visual Inspection |
Check for loose grips, debris on lead screws, and cable wear. |
|
Quarterly |
Lubrication & Cleaning |
Grease the pillars and lead screws; clean the grip faces to prevent slippage. |
|
Annually |
Comprehensive Service |
Full electronic calibration, motor belt inspection, and software updates. |
|
Post-Move |
Re-verification |
Any time a UTM is relocated, it must be leveled and checked for alignment. |
Universal Testing Machine Maintenance Procedure
The UTM machine maintenance procedure should follow a systematic process to ensure that the machine remains accurate and reliable.
Step 1: Visual Inspection
The initial step in the UTM machine maintenance process is to visually inspect the machine frame, grips, crosshead, screws, cables, and display system. It is important to check for any loose parts, worn grips, cracks, and damaged cables.
Step 2: Cleaning the Machine
The next step in the UTM machine maintenance procedure is to clean the machine. Remove any visible dust from the machine surface and grips, as well as any dust particles that may actually come from the sample itself; it has been found that dusting the machine surface can increase the smoothness of the machine's motion.
Step 3: Lubrication of Moving Parts
Lubricating the moving parts of UTM equipment forms part of the equipment maintenance routine. The moving parts of UTM equipment like ball screws and guide rods require lubrication. The reason for lubricating these objects is to reduce friction generated by their movement over time. It also helps in maintaining performance of various operations in product manufacturing.
Step 4: Check Load Cell and Sensors
The next step in the UTM machine maintenance procedure is to check the load cell, extensometer, and displacement sensors. Check whether the readings.
Step 5: Alignment and Grip Check
It is critical to ensure that grips are aligned properly. Failure to align grips will result in uneven force distribution.
Step 6: Software and Electrical Inspection
This step involves checking the software, electrical connections, and cables. Software upgrades may be required.
Step 7: Calibration Verification
This step involves checking calibration using certified reference standards. This will ensure proper force and elongation measurement.
Why It Is Necessary to Perform Regular Maintenance of UTM Machines
The maintenance of UTM machines is required on a regular basis, as the accuracy of the tests conducted depends directly on the machine's condition. Even a small fault in the machine can change the tensile or compression force, which may result in a faulty quality decision.
The first major reason for regular maintenance of UTM machines is the retention of accuracy in tests conducted using these machines. Due to regular usage, there are chances of wear in the load cell, movement of the crosshead, and grips.
The second reason for regular maintenance of UTM machines is machine longevity. Lubrication, cleaning, and replacement of parts will help in avoiding major mechanical damage. The third reason for regular maintenance of UTM machines is to meet industry needs and audits. Many ISO, ASTM, and NABL-based labs require evidence of periodic maintenance and calibration.
It will help in achieving repeatability, which is a significant advantage of using UTM machines. The most important reason for regular maintenance of UTM machines is to enhance the safety of machine operators. Preventive maintenance is an essential and unavoidable step for any manufacturing or testing industry.
Testronix UTM Machine: Best Equipment with Consistent Maintenance
The Testronix UTM Machine is widely preferred in quality labs because it provides accurate results and has strong long-term service support. The machine has a strong mechanical structure, accurate load measurement, and strong gripping mechanisms, making it more efficient and reducing wear and tear.
Our UTM Machines are designed to provide strong support for routine maintenance. This is strongly beneficial for industries that operate in the field of plastics, metals, packaging, PET, and automotive testing. The other advantage of Testronix equipment lies in its ability to reduce downtime.
Conclusion
It is a necessity to maintain a Universal Testing Machine to maintain testing accuracy, machine durability, and quality standards. Choosing reliable equipment, such as the Testronix instruments, can streamline this process due to its strong long-term service support and robust design. A Universal Testing Machine should be maintained when there are unstable readings, high usage cycles, machine movement, and signs of machine wear and tear. It is necessary to maintain a Universal Testing Machine by following a proper maintenance procedure in order to avoid machine failure and maintain machine accuracy.