Project Readiness Package R14600 Rev 4/29/14edge.rit.edu/edge/R14600/public/Final Documents/PRP_1A_Eric_Kutil.pdfChecklist Completed by: Eric Kutil For each discipline, indicate which

Project Readiness Package – R14600 Rev 4/29/14

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INTRODUCTION:

Reciprocating sliding contact test rig Design and build a wear and friction monitor to test various metals

under reciprocating sliding contact at various load and sliding frequencies, under dry and lubricated (with

oil and grease) conditions. The specimen is loaded and then reciprocally slid against a fixed counter body.

The basic geometry of the contact is ball-on-plate, but other geometries can be accommodated by using a

range of simple clamping fixtures (pin-on-plate, cylinder and plate). A linear displacement between ball

and plate, perpendicular to the contact, is induced by a sliding sample table. The normal force is kept

constant during testing. The friction force is continuously measured and stored. Equipment will conform

to ASTM G -133-05, ASTM G-181, ASTM –D-5706-05, and ASTM-D-5707-05.

ADMINISTRATIVE INFORMATION:

Project Name (tentative): Friction Tester – Armature System 1A

Project Number, if known: R14600

Preferred Start/End Semester in Senior Design:

My level of interest in being on this team:

Faculty Champion:

Name Dept. Email Phone

Dr. Iglesias-Victoria ME [email protected] 585-475-7694

Other Support, if known:

Name Dept. Email Phone

Stephen Boedo ME [email protected] 585-475-5214

John Wellin ME [email protected] 585-475-5223

Project “Guide” if known: Gary Werth

Primary Customer: Dr. Iglesias-Victoria, [email protected], 585-475-7694

Sponsor(s):

Name/Organization Contact Info. Type & Amount of Support

Committed

RIT Mechanical Engineering RIT Building 09 - 2125

Fall/spring Spring/Fall

1 2 3 4 5 (most interested)

mailto:[email protected]

mailto:[email protected]


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PROJECT OVERVIEW: Dr. Iglesias-Victoria, a mechanical engineering faculty member, is researching wear and friction

characteristics of materials such as metallic and polymer matrix composites, nanostructured materials, and the use of ionic

liquids and liquid crystals as lubricants or additive of lubricants. Her current research plan is to utilize her experience in

tribology and ionic liquids to develop new lubricants and surface treatments or coatings to improve the wear resistance of

gearboxes and bearings of both land-based and off-shore wind turbines. Senior Design students working on this project will

develop test equipment that can be used in Dr. Iglesias’s lab for this purpose.

This design project is being proposed in two formats: single-team, and multi-team. The former will focus on the project being

completed with one senior design team; the latter will divide the work between two MSD teams that will integrate their

respective designs together. Furthermore, two types of PRPs will be proposed to add flexibility to staffing and possible design

outcomes. Figure 1 below shows the intended breakdown of the R14600 project.

Figure 1: PRP submission layout

Groups 1A and 1B can be paired with groups 2A and 2B in any combination. This PRP will specifically address 1A.

The final, combined deliverable of both teams will be a wear and friction test rig to experiment on various metals with

reciprocating contact at various loads and sliding frequencies, under dry and lubricated conditions, and at temperatures up to

200°C. The basic geometry of the contact is ball-on-plate, but other geometries should be accommodated by using a range of

simple clamping fixtures (pin-on-plate). A linear displacement parallel to the plane of contact between the plate and specimen

will be caused by sliding the two against each other. The normal force exerted on the specimen must remain constant during

testing, and the friction force needs to be continuously measured and recorded. Equipment will conform to ASTM G -133-05,

ASTM G-181, ASTM –D-5706-05, and ASTM-D-5707-05 if required by the customer at the start of the project. Many friction

testers with similar properties exist, however they are all over budget. The challenged with this project is to design a friction

test rig with multiple features for a faction of the cost compared to off the shelf models.

Figure 2: Ball and pin contact


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DETAILED PROJECT DESCRIPTION:

A small MSD team will be responsible for designing and building the armature system (upper half) which will then be

integrated with the reciprocating system (bottom half) to create the proposed friction test rig. This armature has the purpose of

providing a constant and accurate vertical normal force through a single point of contact to a small metallic specimen on the

reciprocating system. The single point of contact will be either a ball or pin which will be place in a special holder and

mounted on the armature. The normal force must be variable up to 20 N in vertical with the contact point. A key factor in the

design is that the weight of the arm must not affect or add to the desired normal force. This means weight of the arm must be

counterbalanced so it applies a 0 N resting force. Another fey feature is that the weight must remain constant throughout the

entire testing range as the specimen wears. The MSD team will consist of mostly ME and IE students and therefore, the system

should be designed as mostly a mechanical system. This armature system must also be able to measure and display the normal and friction force being applied to the

specimen during testing. The data-acquisition hardware and software may be shared between both MSD teams. The data must

be collected and displayed in a manner that requires little technical knowledge by the end user. This system must interface with a reciprocating system being developed in parallel by a different MSD team. The

armature must be fully functional and securely attached to the reciprocating system by the end of MSD. Key interfaces include

the attachment of the armature the base of the reciprocating system, the contact point and a specimen held by the reciprocating

system, and the data acquisition hardware and software being used by the other MSD team. There is a shared budget of $3000-$5000 between both MSD teams, and the expected budget for this team is $1200.

Customer Needs and Objectives:

Completion time One academic year

Fit on desktop 4’x6’; prefer 2’x1’

Contact style Ball/pin, interchangeable

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

Load Release 0N

Test Duration 24Hrs

Data Acquisition Time, friction force, normal force, temperature, frequency

Budget $1,200

● Functional Decomposition:


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● Potential Concepts: Potential concepts, skills, and tasks should not be shared with students.

● Complete friction tester concept sketches

Armature 1A counterbalance sketch


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● Specifications (or Engineering/Functional Requirements):

rqmt. #

Source Function Engr. Requirement (metric)

Unit of Measure

Marginal Value

Ideal Value

Comments/Status Test/Verification

S1 Customer Apply Normal Force

Testing Load Range

N +/- 2% 0.5-20 in steps of .5, 1, 2,

5, 10, 20

Measure load applied to specimen before and during test

S2 Customer Apply Normal Force

Resting load on specimen (no weights added)

N N/A 0

Measure load on specimen with no weights added

rqmt. #


Unit of Measure

Marginal Value

Ideal Value


S3 Customer Transfers Data

Device sends data to Labview

Pass/Fail Other

Program used

Pass

Assess functionality and accuracy

S4 Customer Transfers Data

Measures frictional force on specimen

Pass/Fail Pass Pass

Assess functionality and accuracy

rqmt. #


Unit of Measure

Marginal Value

Ideal Value


S5 Customer Hold Contact

Secure Contact N Holding force > gravitational

force 20

Test the force required for removal

S6 Customer Hold Contact

Accommodate Ball and Pin contact

Pass/Fail Pass Pass

Test if different attachments are possible

rqmt. #


Unit of Measure

Marginal Value

Ideal Value


S7 Customer Overall Assembly

Project Budget

$ 1500 max

1200

Sum costs of entire project

S8 DPL Team

Interface with Reciprocating system

Securely Attach

Pass/Fail >Hand Tight

Requires Tools

Assuming armature will be bolted to base

Simple tools required to assemble/ disassemble


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House of Quality


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● Constraints:

o Budget

o Interfacing with other team

o Physical Size

o Mechanical solution to normal force application

● Project Deliverables:

o Completed reciprocating ball/pin friction tester

o Fully tested machine

o Maintenance and operation documentation

● Budget Estimate: $1200

● Intellectual Property (IP) considerations: N/A

● Other Information: N/A

● Continuation Project Information, if appropriate: N/A

STUDENT STAFFING:

● Skills Checklist: See Appendix.

● Anticipated Staffing Levels by Discipline:

Discipline How Many? Anticipated Skills Needed (concise descriptions)

EE ---- N/A

ME 3 3D CAD, machining and various forms of

analysis must be used to design and build

the armature.

CE ---- N/A

ISE 1 Systems design, ergonomics and project

management will be important for optimal

design.

Other ---- N/A


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OTHER RESOURCES ANTICIPATED:

Describe resources needed to support successful development, implementation, and utilization of the

project. This could include specific faculty expertise, laboratory space and equipment, outside services,

customer facilities, etc. Indicate if resources are available, to your knowledge.

Category Description Resource

Available?

Faculty

Iglasias/Boedo Subject matter expert on

tribology

Wellin Subject matter expert on data-

acquisition

Environment

Machine Shop Need to machine various parts to

create armature

ME Computer Lab Use CAD software to design parts

Lab Space Area to build friction tester in

the lab of Dr. Iglasias

Prepared by: Eric Kutil Date: 5/21/2014


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Appendix 1: Skills Checklist Project name: R14600 Armature Checklist Completed by: Eric Kutil For each discipline, indicate which skills or knowledge will be needed by students working on the associated project, and rank the skills in order of importance (1=highest priority). You may use the same number multiple times to indicate equal rank. Mechanical Engineering

1 3D CAD Aerodynamics

MATLAB programming CFD

1 Machining (basic) Biomaterials

2 Stress analysis (2D) 2 Vibrations

3 Statics/dynamic analysis (2D) Combustion engines

Thermodynamics 4 GD&T (geometic dimensioning & tolerancing)

Fluid dynamics (CV) Linear controls

LabView (data acquisition, etc.) Composites

Statistics DFM

Robotics (motion control)

FEA Composites

5 Heat transfer Other:

Modeling of electromechanical & fluid systems Other:

3 Fatigue & static failure criteria (DME) Other:

3 Specifying machine elements

Reviewed by (ME faculty):

Industrial & Systems Engineering

Statistical analysis of data – regression Shop floor IE – methods, time study

Materials science Programming (C++)

1 Materials processing – machining lab

Facilities planning – layout, material handling DOE

Production systems design – lean, process improvement

3 Systems design – product/process design

3 Ergonomics – interface of people & equipment (procedures, training, maintenance)

Data analysis, data mining

Math modeling – linear programming), simulation Manufacturing engr.

2 Project management DFx -- Manuf., environment, sustainability

Engineering economy – ROI Other:


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Quality tools – SPC Other:

4 Production control – scheduling Other:

Appendix 2: 3 Week Plan

Appendix 3: Cost Breakdown

Item Cost

Apply normal force

Weights or force source $450

All Arm Materials $350

Measure frictional force Strain gauge/sensor $50

Hold contact point Contacts $300


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Securing contact holder $25

Mount to Recip. Group Securing Hardware $25

Total $1,200

Appendix 4: Risk Management

Risk Cause Effect

Likelihood

3=high,

1=low

Severity

3=high,

1=low

Importance Action to Mitigate Action to Remediate

Owner - who

takes action if

necessary?

1

Test Control

System stops

collecting data

Software

Bug/Electrical Issue

Data may be lost, and

a test specimen may

be wasted as a result.

3 3 9

Thoroughly debug and test the

system. stress test the program.

Try to make it crash/stop

collecting data.

Modify code to debug if

possible. Fix wiring/replace

component if that is the root

cause.

Customer, or

MSD Team if

project is not yet

completed

2

Erroneous data

collected from

sensors

Software

Bug/electrical

issue/faulty

component

Data is likely

unusable, and test is

not valid (wasting a

specimen).

3 3 9

Debug and test the system

thoroughly. Run test specimens

and compare measurements to

published results.


possible. Fix wiring/replace

component if that is the root

cause.

Customer, or

MSD Team if

project is not yet

completed

3a

Specimen heaters

malfunction -

produce no heat

Overuse/defective

unit/control system

bug/electrical failure

Specimen is not

heated. Test may be

rendered invalid.

2 2 4

Pick higher quality heating unit,

ensure correct wiring, debug

control system prior to running

tests

Find and fix the cause of the

problem, or purchase a new

unit if the cause is a defective

unit

Customer, or

MSD Team if

project is not yet

completed

3b

Heaters

malfunction -

Produce too much

heat

Overuse/defective

unit/control system

bug/electrical failure

Overheats specimen

and holder, possibly

damaging both and/or

rendering test invalid

1 2 2

Pick higher quality heating unit,

ensure correct wiring, debug

control system prior to running

tests

Find and fix the cause of the

problem, or purchase a new

unit if the cause is a defective

unit

Customer, or

MSD Team if

project is not yet

completed

4Holder

fails/breaksOveruse/Defect Device Unusable 1 3 3

Buy from a reputable company,

add in failsafes and redundancyBuy a new Holder

Customer, or

MSD Team if

project is not yet

completed

5

Arm counter-

weighting system

fails

Unintended

use/damage from

foreign object

Arm no longer exerts

zero normal force

when no weights are

added.

1 3 3

Design a fail-safe solution, or a

solution that minimizes chance

of failure. Redundant systems

Fix counterweight system, or

jerry-rig something until the

original system is fixed.

Customer, or

MSD Team if

project is not yet

completed

6Force-arm has a

structural failure

Unintended

use/damage from

foreign object/ too

much load/fatigue

System becomes

unusable1 3 3

Design a fail-safe solution, or a

solution that minimizes chance

of failure. Redundant systems

Repair arm if possible, or find a

substitute for the arm if

possible.

Customer, or

MSD Team if

project is not yet

completed

7Program crashes

during testsSoftware Bug

Data may be lost, and

a test specimen may

be wasted as a result.

3 3 9

Thoroughly debug and test the

system. stress test the program.

Try to make it crash and look at

causes.


possible. Fix wiring if that is

the root cause.

Customer, or

MSD Team if

project is not yet

completed

8Linear actuation

ceases

mechanical

equipment failure

Wear tester does not

oscillate; unusable

device

1 3 3Pick long-lived equipment that is

designed for extended use.

Purchase a replacement piece

of equipment

Customer, or

MSD Team if

project is not yet

completed

9

Project is not

completed on

time (a single

MSD team)

Inadequate time

management,

understaffed project,

unexpected delays,

design challenges

Projet may be left in

an unusable state.

Work will have to be

handed off to next

group. Customer will

have to delay tests.

2 3 6

Team should decide to what

extent the scope of the project is

feasible (with consideration to

knowledge, funding, and time) as

early as possible and work with

their guide and customer to

change the scope as necessary

Project gets passed on to

another MSD team, or the work

could be passed onto a

graduate student.

Customer

10

off-the shelf model

may be

purchased

A piece of equipment

meating all necessary

standards is found for

a reasonable price.

Project does not make

it to MSD because a

solution to the problem

has been found.

1 3 3 [None - Beneficial to customer] [None - Beneficial to customer] DPL team

11

Measuring friction

force acurately

becomes a

difficult design

challenge

Planned meathod for

measurement fails,

device geometry or

other factors make

measurement difficult.

Device is unreliable,

and potentially

unusable.

2 3 6

Plan accordingly, and look at

known systems to understand

how they measure the frictional

force.

Design a new measurement

method that is compatible with

already-designed components

of the device.

Customer, or

MSD Team if

project is not yet

completed

12 Over budgetSpend too much

money

project reaches a

stand-still or customer

supplies more funding

2 1 2cafefully track all expenses and

add in some wiggle room

ask customer for more funding,

pay out of pocket, look for

grants

MSD team must

communicate

with customer

13LabVIEW needs

to be purchased

LabVIEW and

associated hardware

needs to be

purchased

Budget gets allocated

almost entirely to

LabVIEW

3 3 9

The MSD team should talk to the

customer about this possibility.

Dr. Iglesias is aware that

LabVIEW is a major expense,

and will likely split the cost

between the MSD team and a

grad student's project.

Plan accordingly, and allocate

budget so that money is spent

wisely. Also, more money may

be available from the customer.

MSD team