UMT TriboLabTM for Automotive Applications · and comparison (ranking) Cam and Follower • UMT...
Transcript of UMT TriboLabTM for Automotive Applications · and comparison (ranking) Cam and Follower • UMT...
January 21, 2016 2
Introduction
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Innovation in Automotive
Energy Efficiency
Safety
Environmental Concerns
INNOVATION in
Automotive
Test
ing
Automakers
Research Organizations
Part Suppliers
Product Differentiation
Extent of Value- addition
Comparative Data
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Introduction
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Bruker’s
UMT TriboLab
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UMT TriboLab Applications
Numerous Automotive components can be tested for their Quality
and Performance using UMT TriboLab system - a few examples:
• Paints and coating (Scratch, Hardness)
• Lubricants (Comparative Stribeck Curves)
• Clutch and brake materials (Friction, Wear)
• Bearing (Wear)
• Tires (Friction, Wear)
• Piston ring and cylinder liner (Friction, Wear)
• Elastomers (Shore Hardness, Mechanical Properties)
• Engine valve (Hot Hardness)
• Wind shield (Scratch/Mar Resistance)
• Mirror (Stiction, Scratch Resistance)
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Test Methods
Tribological
• Friction (Static, Dynamic, Stiction)
• Wear and Wear Durability
Mechanical
• Hardness (Classical and Instrumented methods)
• Young’s modulus (instrumented indentation)
• Flexural stress-strain and elasticity in bending
• Scratch Test (Adhesion and Mar Resistance)
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Bruker’s UMT TriboLab
o The system is built on the Universal
Mechanical Test (UMT) platform with precision
control of load, speed, and position.
o Most sophisticated and versatile tribology test
system ever designed
• Modular and Innovative
• Broadest Capabilities
• Unmatched Ease of use
o Real Time Control and Data Analysis software
to ensure high accuracy and repeatability of
test data.
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• Modular and Innovative Design ensures the maximum flexibility
- Single motor to cover full torque and speed ranges
- Easy to configure for any tribological or mechanical tests
- Interchangeable lower drives
• Broadest Capabilities
- Force (1mN to 2kN)
- Torque (up to 5N·m)
- Speed (0.1 to 5000 rpm)
- Temperature (-30 to 1000oC)
- Humidity (5 to 85%RH)
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Bruker’s UMT TriboLab
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Self-centering
Coupler Blind-mate Electrical
Connecters
TriboID Chip
Tool-less
Clamping
Pre
cis
ion
Base-r
ing
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Bruker’s UMT TriboLab
• Unmatched Ease of Use due to Intelligent hardware and
software interfaces making it user-friendly, versatile, and
productive.
- TriboIDTM automatically detects and configures
components that are plugged into the TriboLab system
- TriboscriptTM offers an enhanced and secured scripting
interface with Operator and Expert Modes of scripting
environment for running test at ease vis-a-vis preserving
the universality towards advanced test script
development using test-block methodology.
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January 21, 2016 10
Liquid and Environmental Chambers
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BOR Heating
Chamber
Rotary Humidity
Chamber
Rotary Liquid Chamber Rotary Heating Chamber
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Friction Test
Friction: The resistance force that one surface or object encounters
when moving over another.
o Sledge Friction Test (flat-on-flat) (ASTM D1894)
o Ball-on flat, Pin-on-flat, cylinder-on-flat
Z
X
F
FCOF )(
Sliding
Fz
Fx
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tan
mg
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Sledge Friction
Sliding
Fz
Fx
Dynamic
Static
Sliding Distance
Static and dynamic friction of solid surfaces
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January 21, 2016 13
Lubricant Test: Stribeck Curve
Stribeck curve
• to evaluate lubricants for
their potential applications
and comparison (ranking)
• UMT TriboLab can cover
all three regions in wide
ranges of force, speed,
and temperatures
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Boundary Mixed Hydrodynamic
Piston Ring
Cam and Follower
Engine Bearing
Stribeck Curve of Lube A with ECR
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Comparative Stribeck Curves
Stribeck curves of Lubes A and B showing differences in
Boundary and Mixed regimes
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Boundary Mixed Hydrodynamic
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Wear Durability Test
• Testing tool tip –ball, Rockwell
diamond stylus
• Special probes such as ECR and AE
measurements
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Wear Durability Test of Paints
Wear Durability test results on painted panels using ECR option.
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January 21, 2016 17
Wear Test
Thrust Washer (ASTM D3702-Ring-on-disk)
Test is designed for the evaluation of wear
of bulk materials but this procedure can
also be used for measurement of wear
resistance of a coating. Fz and Torque (Tz)
are measured to obtain the evolution of
COF as function of Time.
Specific wear rate as the amount of
materials removed (mm3) with unit force (N)
and unit relative distance (m) travelled by
the wearing contact. The specific wear rate
is expressed in 𝑚𝑚3
𝑁.𝑚 unit.
Fz
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Wear Test of Coating
Test: 20 N, 300 rpm, 1 hr
Sp. Wear Rate = 6.85 x 10-5 𝑚𝑚3
𝑁.𝑚
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Piston Ring Cylinder Liner Test (ASTM G181 )
Step loading 100 -1600 N and back; Frequency-10Hz; Stroke-10mm
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January 21, 2016 21
Bearing Test with Conformal Contact
Conformal bearing test (BOR type drive): 2kN, 500 rpm; hot oil recirculation;
Torque measured with an inline torque sensor
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Hardness Test
Hardness indicates the resistance of a material against
plastic deformation.
• Hardness Tests: Brinell, Vickers, Knoop,
Rockwell, and Shore
• Instrumented Indentation Test: hardness and
Young’s modulus from load-displacement data
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Brinell, Vickers, Knoop Hardness
Brinell hardness (HB):
HB =2𝐹𝑧
𝜋𝐷 𝐷− 𝐷2−𝑑2
FZ is in kgf, D and d are in mm.
d
D
Fz
Vickers hardness (HV):
HV =2𝐹𝑧sin
𝛼
2
𝑑2
FZ is in kgf, = 136; d = (d1+d2)/2 in mm.
Knoop hardness (HK):
HK =14.229𝐹𝑧
𝑑2
FZ is in kgf, d is the long diagonal in mm.
d1
d2
d
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January 21, 2016 24
Rockwell and Shore Hardness
Rockwell hardness test applies an initial
load (FMinor), increased to a final value
(FMajor), then load is reduced to the initial
value. The difference in tip displacement
between two such minor loads relates
inversely to the hardness of specimen.
Shore hardness follows similar principle as Rockwell, but it differs in
load levels, tip materials, and geometry. It is primarily used for soft
materials such as elastomers.
z
FMinor FMajor
FMinor
Hardness (H): H = k – z.
Example: Hardness measurement in Rockwell C scale: FMinor= 10 kgf;
FMajor= 150 kgf; H = HRC; k = 100; z = permanent tip displacement of
diamond indenter in unit of 2 m.
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Hot Hardness
Hot hardness refers to the
hardness of materials at
elevated temperatures.
Hardness reflects the
strength of materials that
decreases with rise in
temperature. Mechanical
strength of Materials at High
temperature is an important
design parameter.
Usually high temperature mechanical properties of any materials are
evaluated by mechanical and creep rupture tests at elevated
temperatures. These tests are inherently time-consuming and difficult.
Hot hardness test using UMT TriboLab is a faster alternative. UMT
TrboLab has capability of high temperature test up to 1000 C. Engine
valve materials can be evaluated by measuring its hot hardness.
AISI 347 Stainless Steel
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Instrumented Indentation (Oliver-Pharr)
Load vs. Displacement Plots
E = 178.3±3.6 GPa
H = 13.2 ±0.4 GPa
m
fZ hhBF )(
1
max )(max
m
fhZ hhmB
dh
dFS
A
FH Z max
S
Fhh Z
cmax
max
Contact Stiffness (S):
Hardness (H):
Contact Depth (hc):
Force (Fz) vs. Displacement (h):
A
SEr
2Reduced Elastic Modulus (Er):
Contact Area (A): )( chfA
i
i
r EEE
22 111
Elastic Modulus (E) of the specimen is
calculated using:
where, and i are the Poisson’s ratios of the specimen and the indenter,
respectively; Ei is elastic modulus of the indenter
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Three-point Bend Test
ASTM D790 and ISO:178
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Flexural Stress (σf)= 3𝐹𝑍𝐿
2𝑏𝑑2 ;
Flexural Strain (𝜖f) = 6𝐷𝑑
𝐿2
Modulus of elasticity in bending (EB) = 𝐿3𝑚
4𝑏𝑑3
𝑭𝒁
𝑳
𝟐
𝑳
𝟐
𝒃
𝒅
where,
FZ is the force applied; L is the support span
b and d are the width and the depth of the beam, respectively.
D is the maximum deflection at the center of the beam
m is the slope of the initial straight line portion of FZ vs. D plot
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Three-point Bend Test
Fz vs. Z plot of a polymer specimen during 3-point bend test
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Three-point Bend Test
Flexural Stress vs. Flexural Strain of the polymer specimen
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σf = 86 MPa
𝜖f = 0.012
EB = 1.25 GPa
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Three-point Bend Test
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Fz vs. Z plot of a ceramic specimen during 3-point bend test
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Three-point Bend Test
Flexural Stress vs. Flexural Strain of the ceramic specimen
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σf = 98 MPa
𝜖f = 0.00072
EB = 13.9 GPa
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Automotive Paints and Coatings
• Paint is relatively thick. Its primary function is to prevent
materials degradation such as corrosion and improve
aesthetic.
• Coating is relatively thin and it is used for enhancing the
tribological properties such as friction, wear, and scratch
resistance of components.
Paints and coating can be evaluated by scratch test.
Substrate
Top Clear Coat (50 m)
Base Coat (20 m)
Primer (25 m)
Electrocoat (25 m)Phosphate Layer (1 m)
Typical Paint System on an Auto body
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January 21, 2016 33
Scratch Test Capabilities
o Fully conform to ASTM C1624
o Wide force and velocity ranges for scratching
o Zoom-in option on the scratch image
o Image marker to measure scratch dimensions
o All four (X+, X-, and Y+ and Y-) directional scratching
o Automated positioning, focusing, and imaging of the scratch
o Advanced scratch-imaging options to display and saving of scratch
Image with force, AE, ECR, and depth profile data
o Can accommodate scratch tool such as diamond stylus, Vickers, etc.
o Automatic tilt adjustment during scratch depth profile calculation
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January 21, 2016 34
Scratch Tests
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(a) Load and (b) scratch width profiles of a Linear scratch;
(c) Load and (d) scratch width profiles of a Zigzag scratch.
(a) (b)
(c) (d)
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Scratch Tests
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(a) Load and (b) scratch width profiles of a Unidirectional scratch;
(c) Load and (d) scratch width profiles of a X-Y scratch.
(a) (b)
(c) (d)
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Scratch Adhesion Test of Coating
Scratch test results on painted panels using AE and ECR
Scratch Adhesion Scratched
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January 21, 2016 37
Comparative Mar Resistance
Scratch test results using Vickers: Bare Glass A
Mar Resistance: 100 mN
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January 21, 2016 38
Comparative Mar Resistance
Scratch test results using Vickers: Bare Glass B
Mar Resistance: 54 mN
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January 21, 2016 39
Scratch Test with Depth Profile (Prescan-Scratch-Postscan)
Scratch test results on DLC-coating with a diamond stylus
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January 21, 2016 40
Raw-depth profiles of Prescan, Scratch, and Postscan using a
Cap sensor for depth measurements
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Scratch Test with Depth Profile (Prescan-Scratch-Postscan)
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Levelled-depth profiles of Prescan, Scratch, and Postscan using
a Cap sensor for depth measurements
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Scratch Test with Depth Profile (Prescan-Scratch-Postscan)
January 21, 2016 42
Relative-Scratch depth profiles of Prescan, Scratch, and
Postscan using a Cap sensor for depth measurements
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Scratch Test with Depth Profile (Prescan-Scratch-Postscan)
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Summary
o R & D activities are being vigorously pursued by automobile
manufacturers, academia related to automotive, and auto
venders to stand out in the extremely competitive and dynamic
global market. Testing of auto-components for their quality is a
very important activity. UMT TriboLab is leading in such
applications effectively.
o UMT TriboLabTM is built as a universal test system on the
concept of modular and innovative design that covers wide
ranges of test parameters and environmental conditions.
o Integration of Intelligent hardware and software interfaces
makes it extremely user-friendly, most versatile, and very
productive tool for performing tribological and mechanical tests.
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