Design and Fabrication of wear test rig
Wear test rig is a testing machine intended to check wear and grating between at least two surfaces in contact move in respect to one another under controlled conditions. Wear testing rigs are test gadgets used to recreate wear in the research center. Wear happens in a wide range of circumstances. T
2025-06-28 16:31:40 - Adil Khan
Project Title
Design and Fabrication of wear test rig
Project Area of Specialization RoboticsProject SummaryWear test rig is a testing machine intended to check wear and grating between at least two surfaces in contact move in respect to one another under controlled conditions. Wear testing rigs are test gadgets used to recreate wear in the research center. Wear happens in a wide range of circumstances. The utilization of lab testing to check the motor condition offers numerous advantages like straightforwardness of activity, reduced testing cost, acknowledgment of evolving condition, almost exact sign of wear rates.
Project will test AISI 8620 material used in automotive gears under running conditions to check the wear rates at optimum lubicant temperature and load.
Final Result are following.
- Wear test rig
- Testing of specimen will predict causes and the condition responsible for the wear for the material being used (AISI 8620). All these is to low down the aspect of Global energy scenario, to increase the optimum running conditions of automotive, to increase the efficiency of automotive and to maximize life of parts move against each and other.
- In the long run the wear test machine will help the students of mechanical engineering for their MS programs, as it will allow them to test their materials for the completion of final year project.
- Design of wear test rig.
- Fabrication of wear test rig.
- To calculate and analyze the wear rate of AISI 8620 used in dynamics machinery parts and automotive gears.
- Wear test rig is designed by the help of literature review of research papers and by utilizing the equations used for design calculations (static equations for frame, power and torque equations for motor).
- For fabrication the material used for its frame is cast iron.
- FYP machine is pin on disc wear test rig. So, an electric motor 0f 3 HP is utilized that will stimulate the rotation of specimen on stationary pin applying load on specimen.
- Pin is applying load on the specimen and that quantity of load is measured by the load cell. Pin is connected to the load cell from its one end and it’s making an angle of 90 degree with load cell.
- An S type load cell is also utilized to measure the side load vibration or variation and will be attached to the lever arm by mean of supports.
- Two hangers are utilized one in the front of lever arm for applying stationary load and the other at the back acting as dead weight.
- As specimen will be test at optimum running condition so, we have used an inverter that will regulate the RPM of motor in accordance to ASTM G99.
- Moreover, a heater is used to maintain the temperature and for the measurement of its temperature a K type thermocouple is used which is inserted in a bowl. Bowl contain lubricant and the specimen along with shaft rotating the specimen. Shaft is connected to motor by the help of belt drive.
- Lastly, a proximity sensor is used that will give wear rate of AISI 8620 with time at optimum conditions
- The wear test rig is not fabricated in Pakistan and the companies buy these machines for foreign countries which are very costly. The price ranges from 2000$ to 6800$ some of the examples are given bellow. And therefore, there is a need to fabricate these machines in Pakistan at low price.
- Will enable to test automotive material at their optimum running conditions.
- Enable to calculate wear rates.
- Testing of materials used in manufacturing of ships.
- Reducing the Global energy scenario.
- Maximizing the mechanical efficiency of automotive and the life of dynamic parts.
- Improved type of lubricants that can be used in automotive.
- In the long run the wear test machine will help the students of mechanical engineering for their MS programs, as it will allow them to test their materials for the completion of final year project
- Wear test rig machine that will have following capabilities,
- Wear rate at load ranges from 0-50 kg.
- Wear rate at temperature up to 300 degree centigrade.
- Wear rate at different RPMS ranges 400-700.
- Wear rate on wet analysis by using different lubricants.
- FYP mainly focusses on automotive industry to increase the efficiency and life of dynamic parts. The reason of calculating all the above mention points as automotive carry different load moves on different speeds by using different lubricants for their dynamic parts rubbing against each other at different temperatures.
| Item Name | Type | No. of Units | Per Unit Cost (in Rs) | Total (in Rs) |
|---|---|---|---|---|
| Total in (Rs) | 70675 | |||
| beam type load cell | Equipment | 1 | 1600 | 1600 |
| s type load cell | Equipment | 1 | 5000 | 5000 |
| proximity sensor | Equipment | 1 | 2400 | 2400 |
| thermocouple | Equipment | 1 | 350 | 350 |
| aurdinomega 25600 | Equipment | 1 | 1150 | 1150 |
| HX711 chip | Equipment | 1 | 120 | 120 |
| max6675 chip | Equipment | 1 | 350 | 350 |
| 10k volem | Equipment | 1 | 15 | 15 |
| mechanical seal | Equipment | 1 | 1400 | 1400 |
| valves | Equipment | 2 | 175 | 350 |
| machine frame | Equipment | 1 | 25000 | 25000 |
| frame Tyre | Equipment | 1 | 440 | 440 |
| bowl | Miscellaneous | 1 | 700 | 700 |
| electric motor | Equipment | 1 | 11000 | 11000 |
| invertor | Equipment | 1 | 12000 | 12000 |
| testing specimen | Equipment | 1 | 7000 | 7000 |
| heating plate | Equipment | 1 | 1800 | 1800 |