1. 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

2. Agenda Brief Overview Functional Decomposition Concept Generation Engineering Requirements and Feasibility

3. Project Overview Friction tester for Dr. Iglesias Used by herself and students for research Establishes friction test capability in 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

4. Benchmarking Quote from Phoenix Tribology Stroke up to 25mm @ 2Hz, 50mm @ 1Hz Max temperature 400deg C We need 10mm @ 10Hz and 500deg C

5. Functional Decomposition Run a friction test Linearly Reciprocate Contact Point Apply Normal Force Heat SampleTransfers Data Sends Data to Labview Measures Temperature Hold Contact Specimen Secure contact specimen Measures Friction Force Measures Test Duration Hold Bottom Specimen Secure Specimen Control Test Operation Automatic Shutoff Adjust Duration Manual Shutoff Accommodate various Geometries Sends Commands to Tester Shut off after specified time Fail Safe shutoff Maintain Temperature Ramp Temperature Manual Shut Off Button send test duration to tester send Operating Frequency to tester Accomodate ball or pin contact

6. House of Quality Matrix

7. Concept Generation Electric Heating Element Screws OscillationHeatingLoadingHolding ABCD 1Fluid PowerElectricityScrewsMagnets 2MotorFlameWeightsClamps 3MagnetsSteamFluid PowerScrews 4Disk and ArmSprings A2, B1, C1, D2 A1, B1, C2, D2 A4, B1, C2, D3 A4, B3, C1, D3 A3, B2, C3, D1

8. Function-Heat Sample rqmt. #SourceFunction Engr. Requirement (metric) Unit of Measure Marginal Value Ideal ValueComments/StatusRequirement Test S5CustomerHeat SampleRamp Temperature°C/SecTBD Values TBD, Requirement TBC Measure temperature rise/drop over time S6CustomerHeat SampleMaintain Temperature±°C+/- 10%TBD Values TBD, Requirement TBC Measure temperature fluctuation S7CustomerHeat SampleTemperature Range°CN/A~72→500 Marginal TBD, Requirement TBC Measure minimum and maximum Temperature Possible Solutions ●Electricity ●Flame ●Steam

9. Function-Hold Specimen rqmt. #SourceFunction Engr. Requirement (metric) Unit of Measure Marginal Value Ideal ValueComments/StatusRequirement Test S16CustomerHold SpecimenSecure SpecimenNTBD Values TBC Test the force applied to the specimen to hold in position S17CustomerHold Specimen Accommodate various geometries Pass/FailTBDPass Marginal Value TBC Attempt to secure specimens of different sizes and shapes (as defined by customer) S18CustomerHold Specimen Specimen easily removable Minutes to remove TBD1-5 Test the time required to remove specimen Possible Solutions ●Magnets ●Clamps ●Screws

10. Function-Linearly Reciprocate Specimen rqmt. #SourceFunction Engr. Requirement (metric) Unit of Measure Marginal Value Ideal ValueComments/StatusRequirement Test S1Customer Linearly Reciprocate Contact Point Stroke Lengthmm+/- 10%4-10 Measure of operating stroke length S2Customer Linearly Reciprocate Contact Point Frequency rangeHz+/- 10%1-10 Measure of operating frequency Possible solutions Fluid Power Motor Magnets Disk and arm

11. Function-Apply Normal Force rqmt. #SourceFunction Engr. Requirement (metric) Unit of Measure Marginal Value Ideal ValueComments/StatusRequirement Test S3Customer Apply Normal Force Testing Load RangeN+/- 2%0.5-20 Marginal Value TBC, in steps of.05, 1, 2, 5, 10, 20 weigh calibrated weights and calibrate machine loading S4Customer Apply Normal Force Resting load on specimen (no weights added) N+/- 2%0 Marginal Value TBC Measure load on specimen with no weights added Possible solutions Screws Weights Hydraulics/pneumatics Springs

12. Function-Hold Contact rqmt. #SourceFunction Engr. Requirement (metric) Unit of Measure Marginal Value Ideal ValueComments/StatusRequirement Test S14CustomerHold ContactSecure ContactNTBD Values TBC Test the force required for removal S15CustomerHold Contact Accommodate Ball of Pin contact Pass/FailPass Test if different attachments are possible Possible Solutions ●purchase holder ●make holder

13. Function-Transfer Data rqmt. #SourceFunction Engr. Requirement (metric) Unit of Measure Marginal Value Ideal Value Requirement Test S8CustomerTransfers Data Device sends data to Labview Pass/FailPass Assess functionality and accuracy S9CustomerTransfers Data Measures temperature of specimen Pass/FailFailPass Assess functionality and accuracy S10CustomerTransfers Data Measures frictional force on specimen Pass/FailPass Assess functionality and accuracy S11CustomerTransfers Data Measures test duration Pass/FailFailPass Assess functionality and accuracy S12CustomerTransfers Data Sends operating frequency to tester Pass/FailPass Assess functionality and accuracy S13CustomerTransfers Data Sends duration to test tester Pass/FailPass Assess functionality and accuracy Possible Solutions ●thermocouple ●strain gauge ●PC ●DAQ software ●DAQ hardware ●stopwatch

14. Function-Control Test Operation rqmt. #SourceFunction Engr. Requirement (metric) Unit of Measure Marginal Value Ideal ValueComments/StatusRequirement Test S19Customer Control Test Operation Adjustable Test Duration HoursTBD0-24 Marginal Value TBC Run for random durations to see if machine still runs S20Customer Control Test Operation Automatic ShutoffPass/FailFailPass Purposely fail the tester to see if automatic shutoff is activated S21Customer Control Test Operation Manual ShutoffPass/FailPass Test if machine shutoff on demand Possible Solutions ●Manual controls ●Software controlled

15. 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

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