Friction Wear TesterVoice of the Engineer

Chris WilliamsHarrison SpragueBen WolfeEric KutilNoah Barker-Eldon

R14600Customer: Dr. Iglesias

Guide: Gary Werth

4/9/2014

Agenda• Brief Overview• Functional Decomposition• Concept Generation• Engineering Requirements and Feasibility

Project Overview• Friction tester for Dr. Iglesias

• Used by herself and students for research

• Establishes friction test capabilityin a new KGCOE lab

http://www.phoenix-tribology.com/cat/at2/leaflet/te88.htm Fig 1: Example of linear reciprocating friction tester from ASTM G133-05

Benchmarking• Quote from Phoenix Tribology

• Stroke up to 25mm @ 2Hz, 50mm @ 1Hz

• Max temperature 400deg C

• We need 10mm @ 10Hz and 500deg C

Functional DecompositionRun a friction test

Linearly Reciprocate

Contact Point

Apply Normal Force

Heat Sample Transfers Data

Sends Data to Labview

Mea

sure

s Te

mpe

ratu

re

Hold Contact Specimen

Secure contact

specimenM

easu

res

Fric

tion

Forc

e

Mea

sure

s Te

st

Dur

atio

n

Hold Bottom Specimen

Secure Specimen

Control Test Operation

Automatic Shutoff

Adjust Duration

Manual Shutoff

Accommodate various

Geometries

Sends Commands

to Tester

Shu

t off

afte

r sp

ecifi

ed ti

me

Fail

Saf

e sh

utof

f

Maintain Temperature

Ramp Temperature

Man

ual S

hut O

ff B

utto

n

send

test

dur

atio

n to

test

er

send

Ope

ratin

g Fr

eque

ncy

to te

ster

Accomodate ball or pin contact

House of Quality Matrix

Concept Generation

Electric Heating Element

Screws

Oscillation Heating Loading Holding

A B C D

1 Fluid Power Electricity Screws Magnets

2 Motor Flame Weights Clamps

3 Magnets Steam Fluid Power Screws

4 Disk and Arm Springs

A2, B1, C1, D2 A1, B1, C2, D2

A4, B1, C2, D3

A4, B3, C1, D3

A3, B2, C3, D1

Function-Heat Sample

rqmt. # Source Function Engr. Requirement (metric)

Unit of Measure

Marginal Value Ideal Value Comments/Status Requirement Test

S5 Customer Heat Sample Ramp Temperature °C/Sec TBD TBD Values TBD, Requirement TBC

Measure temperature rise/drop over time

S6 Customer Heat Sample Maintain Temperature ±°C +/- 10% TBD Values TBD, Requirement TBC

Measure temperature fluctuation

S7 Customer Heat Sample Temperature Range °C N/A ~72→500 Marginal TBD, Requirement TBC

Measure minimum and maximum Temperature

Possible Solutions● Electricity● Flame● Steam

Function-Hold Specimen

rqmt. # Source Function Engr. Requirement (metric)

Unit of Measure

Marginal Value

Ideal Value Comments/Status Requirement Test

S16 Customer Hold Specimen Secure Specimen N TBD TBD Values TBC Test the force applied to the specimen to hold in position

S17 Customer Hold Specimen Accommodate various geometries Pass/Fail TBD Pass Marginal Value

TBC

Attempt to secure specimens of different sizes and shapes (as defined by customer)

S18 Customer Hold Specimen Specimen easily removable

Minutes to remove TBD 1-5 Test the time required to

remove specimen

Possible Solutions● Magnets● Clamps● Screws

Function-Linearly Reciprocate Specimen

rqmt. # Source Function Engr. Requirement (metric)

Unit of Measure

Marginal Value

Ideal Value Comments/Status Requirement Test

S1 CustomerLinearly Reciprocate Contact Point

Stroke Length mm +/- 10% 4-10 Measure of operating stroke length

S2 CustomerLinearly Reciprocate Contact Point

Frequency range Hz +/- 10% 1-10 Measure of operating frequency

Possible solutions

• Fluid Power

• Motor

• Magnets

• Disk and arm

Function-Apply Normal Force

rqmt. # Source Function Engr. Requirement (metric)

Unit of Measure

Marginal Value

Ideal Value Comments/Status Requirement Test

S3 Customer Apply Normal Force

Testing Load Range N +/- 2% 0.5-20

Marginal Value TBC, in steps

of .05, 1, 2, 5, 10, 20

weigh calibrated weights and calibrate machine loading

S4 CustomerApply Normal Force

Resting load on specimen (no weights added)

N +/- 2% 0Marginal Value

TBCMeasure load on specimen with no weights added

Possible solutions

• Screws

• Weights

• Hydraulics/pneumatics

• Springs

Function-Hold Contact

rqmt. # Source Function Engr. Requirement (metric)

Unit of Measure

Marginal Value Ideal Value Comments/Status Requirement Test

S14 Customer Hold Contact Secure Contact N TBD TBD Values TBC Test the force required for removal

S15 Customer Hold Contact Accommodate Ball of Pin contact Pass/Fail Pass Pass Test if different attachments

are possible

Possible Solutions● purchase holder● make holder

Function-Transfer Datarqmt. # Source Function Engr. Requirement

(metric)Unit of

MeasureMarginal

Value Ideal Value Requirement Test

S8 Customer Transfers Data Device sends data to Labview

Pass/Fail Pass Pass Assess functionality and accuracy

S9 Customer Transfers Data Measures temperature of specimen Pass/Fail Fail Pass Assess functionality and

accuracy

S10 Customer Transfers Data Measures frictional force on specimen

Pass/Fail Pass Pass Assess functionality and accuracy

S11 Customer Transfers Data Measures test duration Pass/Fail Fail Pass Assess functionality and

accuracy

S12 Customer Transfers Data Sends operating frequency to tester

Pass/Fail Pass Pass Assess functionality and accuracy

S13 Customer Transfers Data Sends duration to test tester Pass/Fail Pass Pass Assess functionality and

accuracy

Possible Solutions● thermocouple● strain gauge● PC● DAQ software● DAQ hardware● stopwatch

Function-Control Test Operation

rqmt. # Source Function Engr. Requirement (metric)

Unit of Measure

Marginal Value

Ideal Value Comments/Status Requirement Test

S19 Customer Control Test Operation

Adjustable Test Duration Hours TBD 0-24 Marginal Value

TBCRun for random durations to see if machine still runs

S20 CustomerControl Test Operation Automatic Shutoff Pass/Fail Fail Pass

Purposely fail the tester to see if automatic shutoff is activated

S21 Customer Control Test Operation

Manual Shutoff Pass/Fail Pass Pass Test if machine shutoff on demand

Possible Solutions● Manual controls● Software controlled

Areas of Uncertainty

• Minimum-Ideal metrics unconfirmed with Dr. Iglesias

• Cost of data acquisition hardware/software• Team size and expertise • Change in scope of project if a tester is

purchased

Next Steps

• Meet with Dr. Iglesias to confirm metrics• Research costs of DAQ systems• Continue Feasibility Analysis