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Friction Wear Tester Voice of the Engineer. Chris Williams Harrison Sprague Ben Wolfe Eric Kutil Noah Barker-Eldon. R14600 Customer: Dr. Iglesias Guide: Gary Werth 4/9/2014 . Agenda. Brief Overview Functional Decomposition Concept Generation - PowerPoint PPT Presentation
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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