Development and Testing of Friction and Wear Test Rig

International Journal of Trend in Scientific Research and Development (IJTSRD)
Volume 3 Issue 6, October 2019
@ IJTSRD | Unique Paper ID – IJTSRD28046
Development and Testing
Kingsley N. Nwankwo
Lecturer, Department of Mechanical Engineering, University
ABSTRACT
This research paper presents a friction and wear test rig, developed from
locally available materials. Sizing of the various components of the rig was
done as specified by Society of Automobile Engineers. The required
materials for the test rig were sourced locally, constructed and assembled.
The input shaft was sized to fit in the speed range of available lathe
machines. The test rig was tested using Soy oil, groundnut oil and SAE 40 oil
lubricant. Samples generated from the test rig were analyze
Absorption Spectroscopy to obtain wear metal count in the oil samples.
Results for three wear elements showed that at 40 rpm, copper in oil
samples ranged from 6.2 % - 10.2 % concentration whereas at higher
speeds, a distinct reduction in wear metal concentration was obtained.
Other wear elements followed similar profile. The test rig is capable of
predicting performance of oil lubricants in storage and operating
conditions. The test rig is recommended in industries to increase mean time
between machine failures of production equipment thereby improving
productivity and profitability.
KEYWORDS: Test, Rig, Lubrication, Friction, Wear, Design
1. INTRODUCTION
Friction between two bodies is generally defined as the
force at their surface of contact which resists their sliding
on one another. The friction force, F is the force required
to initiate or maintain motion. If W is the normal reaction
of one body on the other, the coefficient of friction, µ is
defined as [1]:
ߤ ൌ
ி
ே
Wear is a process of gradual removal of a material from
surfaces of solids subject to contact and sliding. Damages
of contact surfaces are results of wear [2]. Types of wear
include Abrasive wear, fatigue wear, corrosion wear etc.
Usually, wear is undesirable, because it makes necessary
frequent inspection and replacements of parts
deterioration of accuracy of machine parts. Wear induces
vibrations, fatigue and consequently failure of the parts.
Lubrication is the application of a lubricant between
contacting surfaces, moving relative to each other with the
aim of reducing friction [3]. In most cases, the applied load
is carried by pressure generated within the fluid due to the
frictional viscous resistance to motion of the lubricating
fluid between the surfaces. Lubrication may be classified
into Boundary lubrication, Eastohydrodynamic and Full
Fluid-film lubrication.
The science and technology of interacting surfaces in
relative motion is called Tribology. Tribology is derived
from the Greek word “Tribos” meaning rubbing. It is the
2019 Available Online: www.ijtsrd.com e
28046 | Volume – 3 | Issue – 6 | September -
nd Testing of Friction and Wear Test Rig
Kingsley N. Nwankwo, Gbashi M. Samuel, Yanshio T. Emmauel
f Mechanical Engineering, University of Agriculture, Makurdi, Benue, Nigeria
This research paper presents a friction and wear test rig, developed from
locally available materials. Sizing of the various components of the rig was
done as specified by Society of Automobile Engineers. The required
ere sourced locally, constructed and assembled.
The input shaft was sized to fit in the speed range of available lathe
machines. The test rig was tested using Soy oil, groundnut oil and SAE 40 oil
lubricant. Samples generated from the test rig were analyzed using Atomic
Absorption Spectroscopy to obtain wear metal count in the oil samples.
Results for three wear elements showed that at 40 rpm, copper in oil
10.2 % concentration whereas at higher
ar metal concentration was obtained.
Other wear elements followed similar profile. The test rig is capable of
predicting performance of oil lubricants in storage and operating
conditions. The test rig is recommended in industries to increase mean time
een machine failures of production equipment thereby improving
Test, Rig, Lubrication, Friction, Wear, Design
How to cite this paper
Nwankwo | Gbashi M. Samuel |
T. Emmauel "Development and Testing
of Friction and Wear Test Rig" Published
in International
Journal of Trend in
Scientific Research
and Development
(ijtsrd), ISSN:
2456-6470,
Volume-3 | Issue
October 2019,
pp.147-150, URL:
https://www.ijtsrd.c
8046.pdf
Copyright © 2019 by author(s) and
International Journal of Trend in
Scientific Research and Development
Journal. This is an Open Access article
distributed under
the terms of the
Creative Commons
Attribution License (CC BY 4.0)
(http://creativecommons.org/licenses/
by/4.0)
Friction between two bodies is generally defined as the
force at their surface of contact which resists their sliding
is the force required
is the normal reaction
of one body on the other, the coefficient of friction, µ is
(1)
Wear is a process of gradual removal of a material from
ject to contact and sliding. Damages
of contact surfaces are results of wear [2]. Types of wear
include Abrasive wear, fatigue wear, corrosion wear etc.
Usually, wear is undesirable, because it makes necessary
frequent inspection and replacements of parts and leads to
deterioration of accuracy of machine parts. Wear induces
vibrations, fatigue and consequently failure of the parts.
Lubrication is the application of a lubricant between
contacting surfaces, moving relative to each other with the
ing friction [3]. In most cases, the applied load
is carried by pressure generated within the fluid due to the
frictional viscous resistance to motion of the lubricating
fluid between the surfaces. Lubrication may be classified
astohydrodynamic and Full
The science and technology of interacting surfaces in
relative motion is called Tribology. Tribology is derived
meaning rubbing. It is the
study of the friction, lubrication
surfaces with a view of understanding surface interactions
in detail and then prescribing improvements in given
applications [4]. Variables in friction and wear testing are
load, velocity, contact area, surface finish, sliding
environment, material of contact face, type of lubricant,
hardness of contact face and temperature [5].
A test rig is an apparatus or equipment used for measuring
the performance of any mechanical equipment [6]. Tribo
test rigs are devices used for investigating friction and
wear. Laboratory friction and wear tests utilize tribometer
systems of simple geometry that may include a rotating
cylinder or disc against which another solid specimen of
different curvature is pressed [7]. When test rigs ar
in combination with ferrographic analyzers and metal
counters, friction and wear can be measured fairly
accurately. These tests assess predominantly the overall
ability of a lubricant to permit rubbing surfaces to operate
without scuffing, seizure o
material destruction.
This study developed and evaluated the performance of a
friction and wear test rig to be used for measuring the
performance of lubricating oils.
2. COMPONENTS AND MECHANISM OF OPERATION
2.1. Components of the Test
The Test Rig is made of the helical spring, shaft, screw,
bevel gears, oil plug, webbed lever, and fasteners.
e-ISSN: 2456 – 6470
October 2019 Page 147
nd Wear Test Rig
Yanshio T. Emmauel
Makurdi, Benue, Nigeria
How to cite this paper: Kingsley N.
Nwankwo | Gbashi M. Samuel | Yanshio
T. Emmauel "Development and Testing
of Friction and Wear Test Rig" Published
in International
Journal of Trend in
Scientific Research
and Development
(ijtsrd), ISSN:
6470,
3 | Issue-6,
October 2019,
150, URL:
https://www.ijtsrd.com/papers/ijtsrd2
Copyright © 2019 by author(s) and
International Journal of Trend in
Scientific Research and Development
Journal. This is an Open Access article
distributed under
the terms of the
Creative Commons
Attribution License (CC BY 4.0)
http://creativecommons.org/licenses/
study of the friction, lubrication and wear of engineering
surfaces with a view of understanding surface interactions
in detail and then prescribing improvements in given
Variables in friction and wear testing are
load, velocity, contact area, surface finish, sliding distance,
environment, material of contact face, type of lubricant,
hardness of contact face and temperature [5].
A test rig is an apparatus or equipment used for measuring
the performance of any mechanical equipment [6]. Tribo
for investigating friction and
wear. Laboratory friction and wear tests utilize tribometer
systems of simple geometry that may include a rotating
cylinder or disc against which another solid specimen of
different curvature is pressed [7]. When test rigs are used
in combination with ferrographic analyzers and metal
counters, friction and wear can be measured fairly
accurately. These tests assess predominantly the overall
ability of a lubricant to permit rubbing surfaces to operate
without scuffing, seizure or other manifestation of
This study developed and evaluated the performance of a
friction and wear test rig to be used for measuring the
performance of lubricating oils.
COMPONENTS AND MECHANISM OF OPERATION
Components of the Test Rig
The Test Rig is made of the helical spring, shaft, screw,
bevel gears, oil plug, webbed lever, and fasteners.
IJTSRD28046

International Journal of Trend in Scientific Research and Development (IJTSRD) @ www.ijtsrd.com eISSN: 2456-6470
@ IJTSRD | Unique Paper ID – IJTSRD28046 | Volume – 3 | Issue – 6 | September - October 2019 Page 148
2.2. Mechanism of Operation
The proposed design was actualized by assembling four
bevel gears (two pinions and two wheels) in a gear
housing. A shaft machined to fit into the jaw of a centre
lathe and welded to one of the pinion gears was employed
to transfer torque from the centre lather to the bevel
gears. While performing a test, the center lathe is used to
turn the bevel gears at selected speeds. Pressure between
the meshing gears is achieved by means of a power screw
connected to a spring of known stiffness. During tests, the
system remains submerged in a lubricant carried by the
gear housing. A thermometer is used to take the
temperature reading of each oil sample after every
running operation. After running a sample at a specific
speed, load and time, the oil sample is drained and taken
for metal count. The efficiency of a lubricant is determined
by the degree to which it reduces the amount of metal
worn into the oil.
3. DESIGN CONCEPT
The design of the various components of the test rig was
done, making reference to the scholarly works of Khurmi
R. S. and Gupta J.K. [8-9].
3.1. Design of the Spring
The spring constant, K can be determined from the
relationship below:
‫ܭ‬ ൌ
ீௗర
଼஽య௡ೌ
(2)
Where G = Shear modulus of material, d = Spring wire
diameter, D = Mean diameter of spring, and na = Number
of active coils.
The shear modulus, G is given as:
‫ܩ‬ ൌ
ா
ଶ(ଵା௩)
(3)
Where E = Young’s modulus and v = Poisson’s ratio.
The mean diameter, D is given as:
‫ܦ‬ ൌ ‫ܦ‬௢௨௧௘௥ − ݀ (4)
Where Douter = Outer diameter.
The maximum force the spring can, Fmax is expressed as:
‫ܨ‬௠௔௫ ൌ ‫ܮ(ܭ‬௙௥௘௘ − ‫ܮ‬௦௢௟௜ௗ) (5)
Where Lfree = Free length of spring, Lsolid = Solid length of
spring.
The maximum shear stress, τmax is given as:
߬௠௔௫ ൌ
଼ௐ஽
గௗయ ‫ܨ‬௠௔௫ (6)
Where W is the Wahl correction factor, defined as:
ܹ ൌ
ସ஼ିଵ
ସ஼ିସ
+
଴.଺ଵହ
஼
(7)
Where C is given as:
‫ܥ‬ ൌ
஽
ௗ
(8)
3.2. Design of Shaft for the Pinion
Since the pinion is subjected to torsion only, the diameter
of the shaft, d may be obtained as follows:
்
௃
ൌ
ఛ
௥
(9)
‫ݎ‬ ൌ
ௗ
ଶ
(10)
Where T = Twisting moment or torque transmitted by
shaft, τ = Shear stress, r = Distance of neural axis from
outermost fibre and J = Polar moment of inertia, defined
as:
‫ܬ‬ ൌ
గ
ଷଶ
݀ସ
(11)
The Torque transmitted by the shaft can thus be expressed
as:
ܶ ൌ
ఛ
ଵ଺
߬݀ଷ
(12)
Or
ܶ ൌ
଺଴௉
ଶగே
(13)
Where: P = Power transmitted by shaft and N = Speed of
shaft in rpm
3.3. Design of the Screw
In order to design a screw jack for a load W, the following
procedure may be adopted:
The core diameter of the screw, dc considering only the
compressive stress, σc may be calculated from:
ߪ௖ ൌ
ௐ
ഏ
ర
ௗ೎
మ (14)
The effort at the handle required to raise the load, Pr is
given as:
ܲ௥ ൌ ܹ‫߮(݊ܽݐ‬ + ߙ) (15)
The effort at the handle required to lower the load, Pl is
given as:
ܲ௟ ൌ ܹ‫߮(݊ܽݐ‬ − ߙ) (16)
Where φ = Angle of friction and α = Screw helix angle.
The torque required to raise the load, Tr is given as:
ܶ௥ ൌ
௉ௗ೘
ଶ
(17)
The torque required to lower the load, Tl is given as:
ܶ௟ ൌ
௉ௗ೘
ଶ
(18)
Where dm = Mean diameter of the screw
This means,
ܶ௥ ൌ ܹ‫߮(݊ܽݐ‬ + ߙ)
ௗ
ଶ
(19)
And
ܶ௟ ൌ ܹ‫߮(݊ܽݐ‬ − ߙ)
ௗ
ଶ
(20)
3.4. Assembly of Test Rig
The test rig was assembled as shown below (Figure 1-3).
The parts include 1. Webbed lever 2. Power screw 3.
Compression spring 4. Test rig casing 5. Gear housing 6.
Pinion shaft 7. Bearing 8. Oil plug 9. Bolt and nut 10 Bevel
gear

Figure1: Test Rig - Front View
Figure2: Test Rig – Sectional Front View
Figure3: Test Rig – Three Dimensional Model View
4. TESTING OF RIG
4.1. Generation of Oil Samples
The test was conducted using Soy oil, Groundnut oil and
SAE 40 lubricating oil. A total of 9 test samples were
generated after running the aforementioned oils at 3
different speeds for a constant load at 5 minutes each as
shown in the Table 1 below.
Table1: Samples Generated for Metal Count
SN SAMPLE SAMPLE DESCRIPTION SPEED (RPM)
1 S1 Soy Oil 40
2 S2 Soy Oil 90
3 S3 Soy Oil 120
4 S4 G/Nut Oil 40
5 S5 G/Nut Oil 90
6 S6 G/Nut Oil 120
7 S7 SAE 40 Oil 40
8 S8 SAE 40 Oil 90
9 S9 SAE 40 Oil 120
4.2. Metal Count
Oil samples generated above were taken for metal count
using Atomic Absorption Spectroscopy. Results for the test
are presented in the section that follows.
5. RESULT AND DISCUSSION
5.1. Result
Line graphs obtained from results of metal count are
shown in Figure 4 – 6. Figure 4 shows the Change in
Percentage Concentration of Metals with Input Shaft
Speed for Soy Oil (S1), Figure 5 shows the Change in
Percentage Concentration of Metals with Input Shaft
Speed for SAE 40 Oil (S3) and Figure 6 shows the Change
in Percentage Concentration of Metals with Input Shaft
Speed for Groundnut Oil (S2)
Figure4: Change in Percentage Concentration of
Metals with Input Shaft Speed for Soy Oil (S1)
Metals with Input Shaft Speed for SAE 40 Oil (S3)

Metals with Input Shaft Speed for Groundnut Oil (S2)
5.2. Discussion
Comparing figure 4 – 6, it is observed that at 40rpm, the
Soy oil sample (S1) contained 10.2 % Cu, while the
Groundnut oil sample (S2), and SAE 40 oil sample (S3)
contained 6.2 % Cu and 6.6 % Cu respectively. The source
of copper could be traced to the gears and bearings of the
friction and wear test rig. The good performance of the
groundnut oil sample at low speed of 40 rpm could be
attributed to the presence of fatty acids in the oil that
formed metallic soaps with the surface of the gears and
bearings thereby producing a lubrication film that was
able to resist friction and wear. This observation agrees
with Nnuka et al. [7] who found that by adding small
quantity of natural oil to mineral oil lubricant, there was
an improvement in wear and friction performance. For the
samples compared above, it is observed that as speed
increased, there is a general drop in percentage
concentration of copper in the samples. This is in
agreement with [10] who observed that at low speeds,
lubricants tend to perform under boundary lubrication
conditions where composition and properties of lubricants
determine lubrication performance. However, as the speed
increases, hydrodynamic lubrication condition sets in and
the primary property that matter is viscosity.
Also from the figures compared, it is observed that at
40rpm, Manganese stood out but as the speed increased,
Magnesium exceeded Manganese while Copper dropped
progressively due to transformation from boundary
lubrication condition to hydrodynamic condition.
6. CONCLUSION
The friction and wear test rig has been designed and
tested. The test rig is used in combination with
ferrographic analyzers, metal counters, gas liquid
chromatographs, etc. for predicting the ability of oil
lubricants to reduce friction and wear. The test rig plays
an important role in lubrication because it is pivotal in
determining the performance of oil lubricants at different
storage and working conditions. The test rig is
considerably cheap compared to the conventional testing
devices.
REFERENCES
[1] Harold, A. R. (2006). “Friction Lubrication and Wear”,
in David T. (ed.) Mechanical Engineering Handbook.
Michigan: McGraw-Hill. Pp 7.1-7.23,
[2] Alfred Z. (2006). Wear Patterns and Laws of Wear –
A Review. Journal of Theoretical and Applied
Mechanics. 44: 219-253.
[3] Reiger N. F. (1967). Lubrication Design, Mechanical
Technology Inc, Latham, New York, pp54-98
[4] Bharat B. (2001); Introduction to Tribology; John
Wiley,
[5] Sanjay K. and Sen S. S. (2014). Wear and Friction in
Journal Bearing: A Review. International Journal of
Engineering and Management Research.
[6] Raajeshkrishna R. G. and Vikrant M. S. (2012). Design
of Journal Bearing Test Rig. Master’s Thesis.
Department of Mecahanical Engineering. Blekinge
Institute of Technology, Karlskrona, Sweden
[7] Nnuka, E. E. Oseni, M. I. and Ette, A. O. (2005).
Evaluation of Tribometric Characteristics of Selected
Natural Oils. Nigerian Journal of Mechanical
Engineering, 3(1), 1-12
[8] Khurmi R. S. and Gupta J. K. (2005a): Theory of
Machies, Eurasias Publishing House Ltd, pp57 – 654
[9] Khurmi R. S. and Gupta J. K. (2005b): Machine
Design, Eurasias Publishing House Ltd, pp56– 87.
[10] Kragelsky I. V., and Alisin V. V. (1982). Friction Wear
Lubrication: Tribology Handbook. McGraw-Hill.
Texas. 264pp

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