1. Project presentation Masters Project in Mechanical Engineering Rensselaer Polytechnic Institute Reduction of Friction in a plastic reciprocating arm By Swamy Ranga

2. Introduction / Problem Description : Forward Stroke Return Stroke Reciprocating plastic part Life - Number of operations External condition Friction

3. Methodology/Approach : Focus on component “ARM” – FMEA No Change in any other component design – High investment, Performance Friction properties Temperature withstand capability Mouldability Availability and Cost Risk mitigation

4. Potential Materials: Liquid Crystal polymer + PTFE (Self Lubricating) Liquid Crystal polymer + Glass + PTFE (Self Lubricating) Relatively unique class of partially crystalline aromatic polyesters based on p- hydroxybenzoic acid and related monomers. PTFE addition make it self lubricating. Glass fibres improves the strength. Features include 1) Good lubricating property with Teflon (PTFE) 2) Superior heat aging performance and retention of properties with temperature 3) Inherently flame retardant 4) Excellent chemical resistance 5) Superior dielectrics over a wide temperature range 6) Outstanding flow - long paths, thin walls, complex shapes 7) Exceptional dimensional stability, low mold shrinkage, low thermal expansion.

5. Potentiel Materials Polybutylene Terepthalate + Glass + Internal lubricant Thermoplastic crystalline polymer, and a type of polyester. PBT is resistant to solvents, shrinks very little during forming, is mechanically strong, heat-resistant up to 150°C (or 200°C with glass-fibre reinforcement) and can be treated with flame retardants to make it noncombustible. Features include 1) Lubricated 2) Flame Retardant 3) Good Chemical Resistance 4) Good Dimensional Stability 5) Good Processability 6) High Impact Resistance 7) Low Moisture Absorption

6. Material comparison :

8. Samples: Minimum 4 samples from each material type Checked for dimensions, finish etc. Assembled in the product and the product marked with material type of Arm. Test setup & details: PLC controlled test setup to fire the voltage & control operation rate and sequence 600 operations per hour for 24 hours a day Target 100,000 operations Test will run till failure or till a certain a degree of confidence.

9. Mechanical Endurance Test Results:

10. Conclusion : Material chosen Liquid Crystal polymer + Glass + PTFE (Self Lubricating) - Material for usage Liquid Crystal polymer + PTFE (Self Lubricating) – Alternate Material