Design and Development of Pin Disc Wear Tester, Part 3: January 2016

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DESIGN AND DEVELOPMENT OF PIN DISC WEAR TESTER, PART 3
Technical Report · January 2016
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2nd Integrated Design Project Conference (IDPC) 2015,
Faculty of Mechanical Engineering, Universiti Malaysia Pahang, 11 Dec 2015.
DESIGN AND DEVELOPMENT OF PIN DISC WEAR TESTER, PART 3
A.Abdul*, I.Abbas, S.Syahirah, M.Fadhli, N.Syafiqah
Faculty of Mechanical Engineering, Universiti Malaysia Pahang,

26600 Pekan, Pahang, Malaysia,
Phone: +60145437753
*Email: ahmad_abdul93@ymail.com
ABSTRACT
Pin on disc wear testing is a method of characterizing the coefficient of friction, frictional force,
and rate of wear between two materials. In application it involves with various type of materials.
This project was carried out the design and fabricate a circular pin disc wear tester with effective
cost and efficient wear tester (pin on disc) used in the metallurgy research field. The purpose of
this project is to study the application of the principle of friction on a pin into the circular disc,
control the speed by using light dimmer controller, (which is it can control the speed in a slow
and high rate of motor speed), and calculate the pressure of two types of pin (mild steel and
aluminum) towards the circular mild disc. The parameters that are going to be used to get the
results are toque, moment, force applied, speed of rotation, duration of test and total revolution
per minute disc rotation. The tachometer will be used to measure the revolution per minute of
the disc surface. By doing that, we can accurately calculate the volume lost and the wear rate
of the materials. As we know that pin wear tester is crucial to the development of new and
improved cost-saving applications, therefore with this product, we hope that we can do
something new and refreshing that can be used by everyone especially in the industry. To
analyze the pin wear tester, finite element analysis (FEA) software is used to estimation the
wear a-priori. As accuracy of calculated wear values strongly depends on the state of stress and
strain in the components, accurate modeling of the state of stress and strain is essential.
Keywords: Pin disc wear; dimmer; FEA.
1
INTRODUCTION
Nowadays, pin wear tester is crucial to the development of new and improved cost-saving
applications, in which are in constant battle with the forces of friction and wear. The purpose
of pin wear tester research is ultimately the minimization and elimination of losses resulting
from wear and friction at all levels of technology where the rubbing of surfaces is involved [1,
2]. Therefore, we are going to design a circular pin disc wear tester. In designing a product, we
need to have many steps that should be taking noted. One of the important steps is to assembly
the parts. If assembly already not precise, therefore we cannot continue our project but need to
make a new part. If the part already welds without precise ways, the part cannot be used
anymore and it will be a loss for us especially in the budget which needs to buy and use a new
materials. All this step are important as pin wear tester is defined as the science and technology
of interacting surfaces in relative motion or in other words, the study of friction, wear and
lubrication [3]. Since then the ‘rubbing’ between two surfaces has caused a sort of revolution,
today this has become a full- fledged branch of science, now known as pin wear tester. The pin
disc wear tester interactions of a solid surface's exposed face with interfacing materials and
environment may result in loss of material from the surface [4, 5]. The process leading to loss
of material is known as "wear". Major types of wear include abrasion, friction (adhesion and
cohesion), erosion, and corrosion [6]. Wear can be minimized by modifying the surface
properties of solids by one or more of "surface engineering" processes (also called surface
finishing) or by use of lubricants [7]. On the other hand, one of the most important aspects of
pin wear tester, and one that is still being investigated today, is how friction generated at the
atomic level. The genesis of friction between two surfaces in relative motion is the key to
finding an answer to the ever-increasing problem of huge financial losses due to wear and
friction [8]. Friction is closely related to the energy dissipation at the surface. Whenever work
is done by a thermodynamic system, heat is generated and this heat is equal to a change in the
internal energy of the system plus the work done by the system. This is known as the first law
of thermodynamics. In the case of friction, when external work is done by a frictional force it
should be equal to the energy dissipated plus the change in the internal energy [9]. Pin wear
tester characterization is critical especially when they are intended to decreased friction and
2
reduced wear as to increase life and performance of materials. This is particularly important in
industries such aerospace, tooling, automotive and others where failure can be catastrophic. Pin
wear tester characterization of wood coatings is critical when intended to ensure wear resistance
parameters in the rough environments wood products are found in. Traditionally wear and
friction testing has been performed with cheap instrumentation providing little reliability. The
direct benefit in improving material surfaces pushes the need for good quantifiable testing.
Besides that, rough surfaces usually wear more quickly and have higher friction coefficients
than smooth surfaces. Surface effects are caused by differences in surface roughness,
microstructure, chemical composition, and residual stress. Besides, the laser-assisted turning
(LAT) of silicon nitride ceramics economically reduces the surface roughness and tool wear in
comparison to only conventional turning process where the effect of applied stress and
temperatures generated at the cutting edge and they were found to influence the wear rate and
hence, the tool life [10].
The wear coefficient is very small (and increases only slowly with displacement amplitude)
over the stick–slip regime; it then rises rapidly with increasing displacement amplitude [11, 12].
Fretting wear occurs if two bodies are pressed against each other and are subsequently subjected
to oscillations with small amplitude [13]. Even if there is no gross slip in the contact, tangential
slip occurs at the border of the contact area leading to wear and fatigue. Fretting wear is a unique
form of material degradation caused by small amplitude oscillatory relative motion of two
surfaces in contact. Fretting wear is typically encountered at relative displacements of less than
300 mm and occurs in either a gross slip regime (where there is slip displacement across the
whole contact), or a partial slip regime (where there are parts of the contact where no slip
displacement occurs) which the fretting wear also being influence by the temperature [14]. The
degradation of surface and subsurface caused by fretting is a complex process involving
friction, wear, plastic deformation, oxidation and crack. Ultimately, fretting maps can be a
practical aid to designers and have been expanded to cover other dimensions (rather than just
those of load and stroke which are most commonly employed). The initiation of the precipitated
carbides slightly increased friction coefficient, but the wear volume increases with the increase
of the carbide precipitation. It was expected that wear of plate materials would start at the
corners in a sliding area because of the thin oil film [15]. Adhesion is major contributor to
3
sliding resistance (friction) and it was inferred in mechanics at least to be operative in wear as
well [16]. Thus abrasive substance are not found, if the amplitude of sliding is greater than
fretting, and if the rate of material loss is not governed by principle of oxidation, then the
adhesive wear is said to occur.
Previous research by Dobromirski has suggested that there are upwards of 50 variables that
affect the fretting wear process, including contact pressure, temperature and surface hardness
[17]. Whilst Archard's wear equation (developed for sliding wear) has been successfully used
to predict material loss in fretting, there are findings to suggest that the relationship between
the resistance to fretting wear and material hardness is complex [18, 19]. Studies by Kayaba
and Iwabuchi have shown that when two steels of different hardness were fretted against each
other, the harder steel wore more than the softer contact; they attributed this effect to protection
of the surface by a black oxide debris layer [20, 21].
The majority of published work on the pin wear tester and wear of non-conformal polymer pairs
relates to the performance of gears [22]. For a pair of gears the dominant operating parameters
such as sliding velocity and load, and the geometric parameters such as module and curvature
of the contacting surfaces vary with the contact position on the tooth profile [23]. Consequently,
gear action is a very complicated process to understand. An alternative method of studying gear
action is to apply the same load and speed conditions to a much simpler geometry [24]. An
example of such a simulation is the use of two cylindrical discs loading against each other in
edge-to-edge contact, each rotating at different speeds. The pin wear tester performance of a
range of engineering polymers and their composites, namely polyoxymethylene (POM),
polyamide 46 (PA46), polyamide66 (PA66), glass–fib rereinforced PA66, PA66 and POM filled
with 20 wt % of polytetrafluoroethylene (PTFE), and short fiber, aramid and carbon-reinforced
PA66 [25]. These materials were tested over a range of rolling speeds and slip-ratios to study
their wear and frictional properties and their potential damage mechanisms [26].
Running-in wear ends when an equilibrium contact surface is established between the
counterparts and a work hardened area is formed near the surface. In this stage, an adhesive
oxide layer can prevent specimens from severe wear [27]. In next stage, wear rate (curves slope)
remains constant due to formation of a stable contact surface between counterparts [28]. A scan
be seen, the wear loss of specimens is decreased with increase in graphite content.
4
Wear rate values for both the pin and sample may also be calculated from the volume of material
lost during a specific friction run. This simple method facilitates the determination and study of
friction and wear behavior of almost every solid state material combination, with varying time,
contact pressure, velocity, temperature, humidity and lubrication [29]. Plasma coatings are a
covering that is applied to the surface of an object. In many cases plasma coatings are applied
to improve surface properties of the substrate, such as appearance, adhesion, wet ability,
corrosion resistance, wear resistance, and scratch resistance [30]. In particular, plasma coatings
are used for engines and other applications alike since they are very thin and can be able to
withstand very high levels of temperature and serve as insulators. A controlled and known
surface friction, wear and adhesion of the coatings are critical to ensure intended performance.
Besides that, using higher loads will create a more aggressive wear rate. However, if the purpose
is to study the surface coefficient while minimizing wear, lower loads can be used [31].
Finite element analysis has been used in pin wear tester and the study of wear to model the
phenomena at widely different length scales. Pin on disc (POD) test covers the laboratory
phenomena for determining wear during sliding [8, 32]. In the POD test, pin is held stationary
under a specified load while the disc rotates beneath it at a constant velocity. According to
ASTM G-99(05) standard specified that pin can have any shape to stimulate a specific contact,
but the spherical tip are often used to ensure normal load transfer to the disc as well as to
establish initial point contact [33]. This test covers a laboratory procedure for determining the
wear of materials during sliding using pin disc apparatus. Materials are tested in pairs under
nominally non-abrasive condition. For the POD test two specimens are required. One, pin with
radius tip is positioned perpendicular to a flat circular disc. The test machine causes either the
disc specimen or the pin specimen to revolve about the disc center. In either case, the sliding
path is a circle on the disc surface. The plate of the disc may be oriented horizontally or
vertically. The pin Specimen is pressed against the disc at a specified load usually by means of
an arm or lever and attached weights. Other loading methods have been used such as hydraulic
or pneumatic. Wear results are reported as volume loss in cubic mm. Wear results are usually
obtained by conducting test for a selected sliding distance and for selected values of load and
speed.
5
FEM consists of a computer model of a material or design that is stressed and analyzed for
specific results. It is used in new product design, and existing product refinement. The main
task of the Finite Element Analysis (FEA) is to identify the nonlinear behavior such as
interaction of one part to another (Pin and Disc) [34]. Non- linear problems pose the difficulty
of describing phenomena by realistic mathematical and numerical models and difficulty of
solving nonlinear equations that result [35, 36]. Pin on Disc contact problem are categorized as
nonlinear because of the stiffness, loads, deformation and contact boundary conditions. The
FEA wear calculations involve solving the general contact problem with the area of contact
between the bodies not known in advance. The analysis is therefore non-linear. This problem
was enforced using penalty function method and geometric description of slave and master
surface. The FEA mesh is constructed using tri-linear isoperimetric 8-noded brick elements
[37]. The problem is modeled as being quasi-static and as such time-independent. In the
structural analysis the degrees of freedom are defined as nodal displacements.
METHODOLOGY
To study wear of the materials, we must simulate the process of wear in a controlled manner
and study the effect on different samples with the same test conditions. One way to perform the
wear is with a pin-on-disk test. In this test, the sample to study is mounted on a rotating stage
and a pin, or ball, comes in contact with the sample surface, with a known force, to create the
wear [38]. A flat or a sphere shaped indenter is loaded on to the test sample with a precisely
known force. The indenter (a pin or a ball) is mounted on a stiff lever, designed as a frictionless
force transducer. As the disk is rotated, resulting frictional forces acting between the pin on the
disk are measured. A ball or pin for the evaluation of wear loss provides several distinct
advantages [39]. Balls of a wide variety of materials are readily available from many suppliers.
Their reproducibility and quality can be excellent ensuring easy accurate comparisons.
Evaluating the wear of the ball or pin provides wear information at the contact point which
stays under load during the full duration of the test [40]. This compared to the base material
that only experiences wear during a comparatively short period of time. Wear test is carried out
to predict the wear performance and to investigate the wear mechanism.
6
Personal and General laboratory safety

1. Do not use any equipment unless you are trained and approved as a user by your
supervisor.
2. Wear safety glasses when conducted the experiment.
3. Put on glove during unpin because the pin is quite hot due to the friction
4. If you have long hair or loose clothes, make sure it is tied back or confined.
5. Keep the work area clear of all materials except those needed for your work.
6. Wear safety shoes in case the weigh is fall during the experiment.
7. Clean up your work area before leaving.
8. Wash hands before leaving the lab and before eating.
Experimental Set Up
There are two experimental of pin wear tester which is laboratory test and component
simulation test. We may use an example to describe the difference among each type of test. A
new surface engineering (SE) technology has been developed, which could be potentially used
to improve the wear resistance of parts for a metal-on-metal hip joint (for human body). Perhaps
the ideal and logical sequence of wear testing in this example will be as follows [41]. For this
project we use two types of material which is aluminum and mild steel. The experiment was
conducted as step below:
Experiment 1: Pin wear tester will be tested manually measured by using Vernier caliper before
and after testing the experimental to measure the pin wear tester of the pins [42].
Experimental variables
Constant variable: Mass/weight (Newton)
Manipulated variables: Materials of pins (Aluminum and Mild Steel)
Responding variable: Length of the pins (mm)
7
Experimental 1 Setup
1. Measure the length of the pin before tighten it into the wear tester by using a Vernier
caliper.
2. Switch on the motor plug and adjust the speed of the motor in the speed controller.
3. Unpin the pin and measure the length of the pin after the experiment.
4. Repeat step 1 – 3 with different material of pin (mild steel and aluminum).
5. The data was recorded.
Experiment 2: Simulation test was calculated by using Finite Element Analysis (FEA) software
to get the friction force applied on the pin wear tester [43].
RESULT & DISCUSSION
Analysis on Pin Disc Wear Tester

The analysis tested done with two type of material on the pin which is mild steel and aluminum.
Before tested, the consideration of the material used is important. An important pin-on-disc
wear test characteristic is the repeated frictional process (the repeated passage of the pin
on the same wear track) so that, because of the brittleness of ceramic, the initial powder
formation and the presence of these wear debris on the worn surface is determinant for
the wear mechanism [44, 45].
Experimental 1
To find the effect of pin in length when it tested in the disc, we decided to set the time set of
disc running in 5 minutes and 10 minutes by putting 20N of weight. In this experiment, the
speed motor is fixed with 2960 rpm because the dimmer difference of high and slow sped is
only 20 rpm. This is too small value, so we decided to use the high speed of motor with dimmer.
Below are our collected results.
8
(i) For 5 minutes testing
Table 1: Result for 5 minutes running

Aluminum Mild Steel
Materials
A1 A2 A3 S1 S2 S3
Length before 98 98 98 99 99 99
(mm)
Length after 97.50 97.40 97.45 98.85 98.80 98.83
(mm)
∆Length (mm) 0.50 0.60 0.55 0.15 0.20 0.17
The pin length differences show that the aluminum is less friction effect compare with mild
steel. Graph 1 shows their comparison.
Length 5 Minutes
99.5
Mild Steel
99
98.5
Aluminium
98
97.5
97
96.5
A1 A2 A3 S1 S2 S3
Length before (mm) Length after (mm)
Graph 1: Differences after and before experimental
9
(ii) For 10 minutes testing
Table 2: Result for 10 minutes running

Aluminum Mild Steel
Materials
A1 A2 A3 S1 S2 S3
Length before 98 98 98 99 99 99
(mm)
Length after 96.95 96.86 96.90 98.65 98.57 98.55
(mm)
∆Length 1.05 1.14 1.10 0.35 0.43 0.45
(mm)
The pin length differences show that the aluminum is less friction effect compare with mild
steel. Graph 2 shows their comparison.
Length 10 Minutes
99.5
Mild Steel
99
98.5
Aluminium
98
97.5
97
96.5
A1 A2 A3 S1 S2 S3
Length before (mm) Length after (mm)
Graph 2: Differences after and before experimental
The result data show that the Aluminum is more effect of friction compare than Mild Steel. This
is because the Aluminum is a very desirable metal because it is more malleable and elastic than
steel. Aluminum can go places and create shapes that steel cannot, often forming deeper or more
intricate spinning. Especially for parts with deep and straight walls, aluminum is the material
10
of choice. Steel is a very tough and resilient metal but cannot generally be pushed to the same
extreme dimensional limits as aluminum without cracking or ripping during the spinning
process [46-48].
While malleability is very important for manufacturing, aluminum’s greatest attribute is that it
is corrosion resistant without any further treatment after it is spun. Aluminum doesn’t rust. With
aluminum there is no paint or coating to wear or scratch off. Steel or “carbon steel” in the
metals world (as opposed to stainless steel) usually needs painted or treated after spinning to
protect it from rust and corrosion, especially if the steel part will be at work in a moist, damp
or abrasive environment [49, 50].
Experiment 2
Stress analysis on Aluminum Alloy 6061-O -Brick when 20 N load was applied.
Table 3: Specification of Aluminum Alloy 6061-O -Brick
11
Figure 1: Result analysis of Aluminum
Stress analysis on Mild Steel when 20 N loads were applied.

Table 4: Specification of Mild Steel
12
Figure 2: Result analysis for Mild Steel
From the FEA figure analysis, the high impact of friction is on aluminum pin. This is due to the
reason of the characteristic of the material used. But for mild steel it actually has the impact but
it’s too little friction on the disc. The load applied on the tester is to balance the weight of the
test when it’s running. The weight help to stabilize the test rig from vibration when the motor
switch on. Therefore, the most suitable material use for the experiment is depends on their aim
of the product function.
CONCLUSION
In this pin disc wear tester project, test setup was modeled by using elastoplastic finite element
method (FEM) for Aluminum Alloy 6061-O –Brick and Mild Steel with 20N force is applied
and 2940 and 2960 rpm speed using FEM. The FEM model was analytically validated and
optimum mesh size for the contact elements were determined by comparing the maximum
contact pressure from elastic analysis result with analytical results from Hertz contact theory
13
applied to the pins. Using this optimum mesh size elastoplastic FEM analysis was carried out
to determine the state of stress and strain in the pins for different speed of the motor. From the
FEM analysis, Aluminum shows the low minimum and maximum value of stress von Moses
(factor of safety) 0.099 and 2.311 N/m2 which is lower compared to Mild Steel. For Mild steel,
the minimum and maximum values of stress von Moses (factor of safety) are 23.006 and
581.123 N/m2. The von-Mises stress reduces for elastoplastic model as compared to elastic
model. With increasing friction, both equivalent plastic strain and von-Mises stress increase.
From these, it can be concluded that, aluminum is more effect of friction compared to mild
steel. Besides that, experiment 1 show that aluminum has shorter length of pins than mild steel.
In the other hand, the design consideration of the bolt is safely to be used as can be seen from
the results and Figure 3. In addition, we have reached our objective which are to study the
application of the principle of friction and wear, design consideration for the system,
elastoplastic analysis of the pin on disc by using finite element method (FEM), state of stress
and state of strain in pin on disc, calculate the moment of the arm and calculate the pressure of
pin towards the specimen. From the calculation, the pressure of pin towards the specimen is
252.61kPa.
ACKNOWLEDGEMENT
We would like to express my deepest gratitude to Mechanical System Design lecturer, Dr.
Muhamad for giving us the opportunities to do this project. Besides that, we would like to thank
our supervisor, Dr. Kumaran for his guidance during our project.
We also would like to give an honorable respect to friends for their moral support during this
training. Lastly, we would also like to expand our deepest gratitude to all those who have
directly and indirectly guided us in writing this report.
14
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DESIGN AND DEVELOPMENT OF PIN DISC WEAR TESTER, PART 3

Technical Report · January 2016

Ahmad Abdul Muhammad Amin Fadhli

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DESIGN AND DEVELOPMENT OF PIN DISC WEAR TESTER, PART 3

A.Abdul*, I.Abbas, S.Syahirah, M.Fadhli, N.Syafiqah

Faculty of Mechanical Engineering, Universiti Malaysia Pahang,

Keywords: Pin disc wear; dimmer; FEA.

Personal and General laboratory safety

RESULT & DISCUSSION

Analysis on Pin Disc Wear Tester

(i) For 5 minutes testing

Table 1: Result for 5 minutes running

Length before (mm) Length after (mm)

Graph 1: Differences after and before experimental

(ii) For 10 minutes testing

Table 2: Result for 10 minutes running

Length before (mm) Length after (mm)

Graph 2: Differences after and before experimental

Figure 1: Result analysis of Aluminum

Stress analysis on Mild Steel when 20 N loads were applied.

Figure 2: Result analysis for Mild Steel

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