Use of the One Sided Template

Tensilkut one sided templates are used of preparation of either very small specimens or specimens with odd contours.  One sided templates have set screws located in the top bar of the template which applies pressure to the clamping bar to hold the specimen steady during the machining operation.

Loosen the set screws to release the clamping bar, which slides up and down on the shoulder pins at either end of the template.  Insert the prepared specimen blank into the template through the side; be certain that it is pushed back such that one entire side of the specimen blank rests against the back wall of the template.  Tighten down the set screws to hold the blank firmly.  Due to the unique low cutting forces involved with Tensilkut, only moderate pressure is required to hold the sample during the machining operation.  The template is basically a holding fixture, and not a vise – excessive pressure in the socket screws could result in deformation of the template assembly.

The contour of the test specimen is controlled by the contour of the hardened top bar of the template, which is riding along the guide sleeve of the control unit. This guide sleeve determines the final width of the test specimen, while the master template controls the configuration of the gauge area.

The sleeve is adjusted by the micrometer dial measured in .001” divisions, with a complete revolution of the dial equal to .050”.  Turn the micrometer dial to full out (counterclockwise, as in unscrewing a bolt), until the stop is reached, and the indicator points to 50 on the dial.  This is the finishing position for the guide sleeve – it is in the closest proximity to the cutting bit when a sample is completely machined.  To machine a ¾” wide sample to .500” gauge width, a total of .250” must be taken off (.125” per side).  Starting with the dial on 50 and the guide sleeve closest to the cutter, turn the dial so that the slide moves outward .125”, or a distance equal to the total amount which must be taken off that side.  With the template against the guide sleeve, the sample will just contact the cutter.

Setting the dial on the Tensilkut machine

Turn on the motor on the Tensilkut machine.  Bring the left end of the contoured section of the master template containing the sample in contact with the sleeve, and with moderate hand pressure and a continuous motion, move the template across the table top in contact with the sleeve until the right end of the contoured section is reached.  With the previous adjustment of the guide sleeve as above, the cutter will just touch the sample when the template is moved against the guide sleeve.  To begin the first actual contour cutting of the sample, the sleeve must be moved inward an amount equal to the depth of the first machining cut.  Again, bring the left end of the contoured section of the master template into contact with the sleeve, and move the template across the table top as described above, repeating this motion alternated with moving the sleeve inward an amount equal to the depth of the first cut until the machining of that side of the sample is complete.  Ideally, the final pass should be a light pass of approximately .001” to .003” depth, for the optimum surface finish.

Please note that, when the first side is complete, the sample’s finished edge will appear slightly oversized in relation to the contoured edge of the template

Upon completion of the first side, remove the partially machined specimen from the template and flip it over such that the contoured edge will be against the back bar of the template, and the uncontoured side will be visible.  Please note that we do not recommend flipping the specimen end for end as this could result in improper alignment of the shoulders and radii from side to side.

Reversing the sample within the template

After the specimen has been turned around within the template, the micrometer control must be readjusted to its starting position, that is, with the guide sleeve as far forward as it was when the initial cut was made on the first side of the specimen.

The machining procedure used to prepare the first contoured edge should be repeated for the second side.  Please note that, again, the sample’s finished edge will appear slightly oversized in relation to the contours of the template.  The sample, when removed from the template, will have contours in accordance with the specification required.

September 11, 2001: We Should Never Forget

From The Island at the Center of the World by Russell Shorto:

“Because of its geography, its population, and the fact that it was under the control of the Dutch (even then its parent city, Amsterdam, was the most liberal in Europe), this island city would become the first multiethnic, upwardly mobile society on America’s shores, a prototype of the kind of society that would be duplicated throughout the country and around the world. It was no coincidence that on September 11, 2001, those who wished to make a symbolic attack on the center of American power chose the World Trade Center as their target. If what made America great was its ingenious openness to different cultures, then the small triangle of land at the southerntip of Manhattan Island is the New World birthplace of that idea, the spot where it first took shape….”
September 11 is a day to celebrate the American spirit of independence, innovation, courage and tolerance, which have caused our country to be so great.  We will never forget those innocent civilians who died at the hands of terrorists who do not share these values.  We will never forget those who were in New York that day whose lives were forever altered by these unforgivable acts of terror.  Our sympathy goes out to those in other countries who live with acts of terror and brutality more often than we do.  We will never forget.

Impactmill

The Impactmill accurately notches plastic and non-metallic materials in accordance with ASTM D256 or ISO 180.  The totally enclosed ½ HP motor rotates a precision ground, single tooth cutter at 1000 RPM.  One or more prepared .500” wide blanks are clamped in the Impactmill’s holding fixture; a rotating cutter notches the specimens as the handwheel is cranked to move the fixture through the cutter’s path.  A micrometer control is used to raise and lower the notching cutter on the Impactmill.  To check the depth of the notch, a micrometer with a knife edge is mounted on the unit.  It is used to accurately measure the critical distance between the tip of the “V” notch and the back of the izod or charpy impact bar.  As with all Tensilkut equipment, the Impactmill is designed for location in the laboratory, and can be operated by technicians with no machining experience.

Impactmill for notching plastic izod and charpy test bars

Tensilmark

The Tensilmark is a compact, freestanding unit designed to scribe gauge marks on prepared flat or round specimens made of most machineable materials.  The marks are accurately produced on 1” or 2” centers, within ASTM tolerances of +.002”.  A floating steel bar contains two hardened steel scribe pins for rapid and consistent elongation marks on specimens.

60-32 Tensilmark

Flat specimens are held in place in the Tensilmark by a positioning bar located in front of the floating steel bar.  The Tensilmark model designed for marking round specimens holds the piece to be marked in a pair of “V” blocks.

For those with custom marking requirements, the Tensilmark can be manufactured with special pins for metric measurements, or for longer samples.

New Website

The new website is up and running! Come see new photos, expanded information on machines, templates and Tensilbits. We also have a special page with the basic information on the machines available in Spanish. Of course, if you have any questions, please leave a comment or email us through our website.

New Tensilkut Website

Coming next week: the updated Tensilkut website at www.tensilkut.com !

There will be more information than ever on the Tensilkut machines and accessories, as well as new pictures.  Of course, we will continue to write articles for this blog.  Should you have questions, or something you’d like to see here, please leave a comment.  We’re happy to hear from you.

Tensilkut II in operation

Instructions for Use of 2-Sided Template

Tensilkut two sided master templates are preferred for cutting most specimen configurations, because both sides of the sample can be cut without removing the partially completed specimen from the template.

Loosen the two socket screws on the top of the template saddles with the allen wrench provided.  The clamping bars will be free to move.  Insert your prepared specimen blank between the thin, moveable bar and the lower, fixed bar until the sample end butts up against the stop pin at one end of the template.

Tighten the two socket screws against the clamping bar with firm pressure, until the sample is secure, using the supplied allen wrench only if necessary.  Due to the unique low cutting forces involved with the Tensilkut, only moderate pressure is required to hold a sample during the machining operations.  The template is basically a holding fixture, and not a vise – excessive pressure in the socket screws could result in deformation of the template assembly.

The contour of the test specimen is controlled by the contour of the top bar of the template, which is riding along the guide sleeve of the control unit.  This guide sleeve determines the final width of the test specimen, while the master template controls the configuration of the gauge area.

Proper grip for use of Tensilkut Template

The guide sleeve is adjusted by the micrometer dial measured in .001” divisions, with a complete revolution of the dial equal to .050”.  Turn the micrometer dial to its full out position (counterclockwise, as in unscrewing a bolt), until the stop is reached, and the indicator points to 50 on the dial.  This is the finishing position for the guide sleeve (in closest proximity to the cutting bit when a sample is completely machined).  To machine a ¾” wide sample to .500” gauge width, a total of .250” must be taken off (.125” per side).  Starting with the dial on 50 and the guide sleeve closest to the cutter, turn the dial so that the slide moves outward .125”, or a distance equal to the total amount which must be taken off that side.  With the template against the guide sleeve, the sample will just contact the cutter.  Turn the motor on with the switch located on the lower section of the motor.  Bring the left end of the contoured section of the master template containing the sample into contact with the sleeve, and with moderate hand pressure and a continuous motion, move the template across the table top in contact with the sleeve until the right end of the contoured section is reached.  Rotate the template 180 degrees, so the uncut side is closest to the cutter, and repeat this motion.  To begin the first actual contour cut of the sample, the sleeve must be moved inward an amount equal to the depth of the first machining cut.  Again, bring the left end of the contoured section of the master template in contact with the sleeve, and move the template across the table top as described above, rotate to cut the other side, and repeat until the machining of the sample is complete.  It is advisable to make the last pass no more than .001” to .003” deep, to achieve the optimum surface finish.  Please note that the sample’s finished edge will appear slightly oversized in relation to the contoured edges of the template.  The sample, when removed from the template, will have contours in accordance with the specification required.

Special Master Templates

SPECIAL MASTER TEMPLATES

Should the standard master templates we have available not suit your exact requirements, special master templates can be designed to meet almost any testing specification, including ISO, JIS, DIN, BS and EN standards.

Test specimens can be prepared from strips varying in length from 2” to 24”, and width from ¼” to 6”.  Gauge sections of the templates can be designed with or without blended tapers.  A template can include drill bushings for precision alignment of holding pin holes for elevated temperature testing or for use with certain grips.  Custom shapes have been designed for longitudinal testing of curved tube sections, while others have been built to machine specimens from welded sections.

Should your testing program require special dimensions, or if your samples include one or more of the unusual conditions listed above, please forward a sketch of the completed specimen, including tolerances and desired taper, to our Engineering Department for a quotation.  Basic sketches for tensile and tensile-impact specimens, indicating the required dimensions, are shown below.  These can be copied, and used to create a sketch of the sample for quotation, if desired.

Standard Tensilkut Templates

Because of the wide variety of specifications in use worldwide for testing of different materials, the Tensilkut machine does not include any standard templates.  All standard templates available for Tensilkut machines are listed herein, and can be ordered with the Tensilkut machine, or at a later date.  We have all standard templates in stock for immediate delivery.

To prepare a test specimen, a rough sheared or sawn strip which is the overall width of the finished specimen is inserted into the template between the upper and lower guide bars, and is not removed from the template until both sides of the specimen are completely machined.  This reduces errors caused by reversing samples, as required by conventional milling.  Where the finished specimen is too small to be held securely in a conventional two-sided template, a one-sided template is used.  A sample which requires machining along its entire length is also prepared with a one-sided template.  As with the more commonly used two-sided templates, any tapers are accurately blended into the template bars, eliminating the need for costly hand finishing.

Model	Specification	Gauge Size
50-14	ASTM E8 Tensile	.500” x 2”
50-24	ASTM E8 Subsized Tensile	.250” x 1”
50-34	ASTM E8 Subsized Tensile (Modified)	.250” x 2”
50-44	ASTM D638 Type I	.500” x 2”
50-52	ASTM D638 Type II	.250” x 2”
50-57	ASTM D638 Type III	.750” x 2.25”
50-62	ASTM D1622 Type S Tensile Impact	.125” x .500”R
50-67	ASTM D1622 Type L Tensile Impact	.125” x .375”
50-72	ASTM D790 Flexural	.500” wide x 4”-8” long
50-77	ASTM D790 Flexural	1.000” wide x 4”-8” long
50-82	ASTM D695 Compression	Gauge Section: .500”x1.5”
50-87	ASTM D695 Compression	To Square Ends: 3.13”
50-92	ASTM D412 Die C	.250” x 2.32”
50-97	ASTM D412 Die D	.125” x 1.31”

Please call or email for a quotation on the template you need.

Tensilgrind for Hard Metals

Tensilgrind is a precision contour grinding machine designed for the preparation of physical test specimens from high hardness metal foil and sheet. Tensilgrind employs the basic principle of Tensilkut, wherein a precision master template is manually guided across the table surface with the removal of metal accomplished in a series of light grinding passes.

Tensilgrind for Hard Metals

Tensilgrind is designed to be located in the metallurgical laboratory, so it is available for grinding test specimens as they are needed, rather than waiting for them to be finished by a machine shop in days or weeks. Laboratory personnel without previous machining experience can readily grind specimens from hard metals and super alloys, resulting in a greatly reduced per specimen cost.

The formed grinding wheel with a ½” hub shaped to a 5/16” width obtains minimum wheel contact with the specimen, while providing maximum wheel rigidity. A radius dressed on the periphery of the wheel by a built in diamond wheel dresser reduces the contact of the wheel with the specimen to a small point for minimum generation of heat.

Tensilgrind control head and Grinding Wheel

Tensilgrind templates are interchangeable with the Tensilkut machines, enabling the user of both machines to have just one set of templates. Accordingly, the Tensilgrind is offered with three different control head heights, although the maximum capacity of any machine is the same. The limitation on the thickness of the material which can be prepared on the Tensilgrind is caused by the radius of the grinding wheel, which would imprint upon too thick a sample.