Manual Tribometru

CETR UMT Multi-Specimen Test System
Hardware Installation & Applications Manual
UMT
Multi-Specimen Test System Hardware Installation & Applications Manual
1/28/09
Center For Tribology 1715 Dell Ave, Campbell CA 95008, USA Phone 408-376-4040 Fax 408-376-4050 Customer Service 408-376-4051
15 YEARS OF LEADERSHIP IN MECHANICAL AND TRIBOLOGY TEST INSTRUMENTATION
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IMPORTANT
User Information
WARNING
The UMT Multi-Specimen Test System uses computer controlled motorized positioning systems that have the potential to cause damage or injury if used improperly. Do not place hands in the testing area while a test is in progress. Keep test area clear of all loose objects which may cause damage or injury when motors are operated. All motors will be instantly disabled by pressing the red Emergency Stop button on the lower front panel of the testing unit.
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Table of Contents
1 Overview _______________________________________________________________________ 5 2 Hardware Description ____________________________________________________________ 6
2.1 2.2 The Basic System ___________________________________________________________________ 6 Typical Configuration _______________________________________________________________ 7
3 UMT System Installation and Setup _________________________________________________ 8

3.1 3.2 Unpacking the system _______________________________________________________________ 8 Connecting the System_______________________________________________________________ 8 10 11 11 13 14 15 15 16 16 17 18 19 19 19 20 21 21 21 22 22 22
3.2.1 Installing Components _________________________________________________________________ 3.2.2 Force Sensors _________________________________________________________________________ 3.2.2.1 2-D Force Sensors ___________________________________________________________________ 3.2.2.2 6D Torque/Force Sensors _____________________________________________________________ 3.2.3 Suspensions, Adapters, and Upper Specimen Holders________________________________________ 3.2.4 Changing Friction/Load Sensors _________________________________________________________ 3.2.5 Force Mounting Extension Blocks ________________________________________________________ 3.2.6 Lower Specimen Motorized Drives and Tables _____________________________________________ 3.2.6.1 Rotational Motion Drives with Specimen Table, with or without encoder _____________________ 3.2.6.2 Reciprocating Motion Drives: _________________________________________________________ 3.2.6.3 Block-On-Ring Drives: _______________________________________________________________ 3.2.6.4 Changing Lower Specimen Drives ______________________________________________________ 3.2.7 Additional Sensors_____________________________________________________________________ 3.2.7.1 Electrical Contact Resistance Measurement and Recording option ___________________________ 3.2.7.2 Temperature Measurement and Recording Model ________________________________________ 3.2.7.3 DC Voltage Measurement and Recording Model VMR-3 ___________________________________ 3.2.7.4 Contact Acoustic Emission (AE) Detector Model AE-5 _____________________________________ 3.2.8 Upper Specimen Suspensions ____________________________________________________________ 3.2.9 Upper Specimens and Specimen Holders __________________________________________________ 3.2.10 Lower Specimens and Specimen Holders __________________________________________________ 3.2.11 Specialized Holders and Specimens _______________________________________________________
3.3
3.3.1 Motorized specimens check _____________________________________________________________ 3.3.2 Instrument check ______________________________________________________________________ 3.3.2.1 Force/Load Sensors __________________________________________________________________ 3.3.2.2 Acoustic Emission Sensor _____________________________________________________________ 3.3.2.3 Electrical Contact Resistance Sensor____________________________________________________
Preliminary Mechanical and Electrical Checkout _______________________________________ 23 23 24 24 25 26 Ball/Pin-on-Disk Friction Test _______________________________________________________ 27 Ball/Pin-on-Disk System Setup___________________________________________________________ 27 Ball/Pin-on-Disk Test Script Parameters __________________________________________________ 28 Stribeck Test ______________________________________________________________________ 30 Stribeck Test System Setup _____________________________________________________________ 30 Stribeck Test Script Parameters _________________________________________________________ 30 Ball/Pin-on-Flat Reciprocating Wear Test _____________________________________________ 34 Ball/Pin-on-Flat Wear Test System Setup __________________________________________________ 34 Ball/Pin-on-Flat Wear Test Script Parameters ______________________________________________ 35
4 Typical Test Procedures __________________________________________________________ 27

4.1
4.1.1 4.1.2
4.2
4.2.1 4.2.2
4.3
4.3.1 4.3.2
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4.4
4.4.1 4.4.2
Block-on-Ring Test ________________________________________________________________ 36 Block-on-Ring Test System Setup ________________________________________________________ 36 Block-on-Ring Test Script Parameters ____________________________________________________ 38
4.5
4.5.1 Micro-Scratch Test System Setup ________________________________________________________ 4.5.2 Micro-Scratch Test Script Parameters ____________________________________________________ 4.5.2.1 Test script parameters for micro-scratch test with constant load _____________________________ 4.5.2.2 Test script parameters for micro-scratch test with linearly increasing load ____________________ 4.5.3 Typical Micro-Scratch Experimental Results: ______________________________________________
Micro-Scratch Test ________________________________________________________________ 39 39 40 40 41 42 Micro-Indentation Test _____________________________________________________________ 44 Micro-Indentation System setup _________________________________________________________ 44 Micro-Indentation Test Script parameters _________________________________________________ 46 Micro-Indentation Data Processing with Data Viewer _______________________________________ 48 Mechanical (Combined Tension or Compression, and Torsion) Testing _____________________ 50 Introduction __________________________________________________________________________ 50 Mechanical Test System Setup ___________________________________________________________ 50 Mechanical Test Script Parameters _______________________________________________________ 51 Processing Mechanical Test Data Using UMT Viewer________________________________________ 53 Typical Mechanical Test Results _________________________________________________________ 53 Summary ____________________________________________________________________________ 57
4.6
4.6.1 4.6.2 4.6.3
4.7
4.7.1 4.7.2 4.7.3 4.7.4 4.7.5 4.7.6
5 Application Notes for Various ASTM Tests __________________________________________ 58

5.1 Pin-on-Disk Wear Test Using the Micro-Tribometer mod. UMT-2 with Rotational Motion Drive ASTM G99-95 __________________________________________________________________________ 58 5.2 Ball-on-Flat Sliding Wear Test using the Micro-Tribometer mod. UMT-2 with Linear Reciprocating Motion Drive - ASTM G 133-95 _______________________________________________ 60 5.3 Standard Test Method for Ranking Resistance of Plastics to Sliding Wear __________________ 63 5.4 Scratch Hardness Test Using a Diamond Stylus on the Micro-Tribometer mod. UMT-2 - ASTM G171-03 _______________________________________________________________________________ 65 5.5 Vickers Hardness Test Using a Diamond Indenter on the Universal Materials Tester mod. UMT-3 or Apex - ASTM E92-82 __________________________________________________________________ 67 5.6 Standard Test for Wear Rate and Coefficient of Friction of Materials in Self-Lubricating Rubbing Contact with a Thrust Washer Using the Micro-Tribometer mod. UMT-2 - ASTM D3702-94 ________ 69 5.7 5.8 Cross-Cylinder Test using Micro-Tribometer mod. UMT-2 - ASTM G83 96________________ 73 Pin Abrasion Testing Using the Micro-Tribometer UMT-2 - ASTM G132-96 ________________ 75
6 Calibration Procedures __________________________________________________________ 86

6.1 Force Sensor Calibration Procedure __________________________________________________ 86
7.
Six-dimensional Sensor (6D) System Setup _________________________________________ 89
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Overview
The UMT Multi-Specimen Test System can be used effectively for the tribological testing of ferrous and non-ferrous metals, plastics, ceramics, paper, composites, thin and thick coatings, as well as of solid lubricants, lubricating fluids, oils and greases. Various common tribology test modes are available, including: Pin on disc Ball on disc Ball on one, two or three balls Pin on V-block Block on ring Disc on disc (flat on flat) Screw in nut
The UMT can accommodate both upper and lower samples of practically any shape. The upper specimen is connected to a vertical linear motion system that has a travel length of 150 mm. Wear measurements can be performed by the instrument to an accuracy of 50 nm. A precision spindle can rotate the lower specimen at speeds from 0.001-rpm up to 5,000-rpm. Ultra-accurate strain-gauge sensors perform simultaneous measurements of load and torque in two to six axes. The forces can be measured precisely in the ranges from milligrams to kilograms, with a resolution of 0.00003% of the full-scale and very high repeatability. 15 YEARS OF LEADERSHIP IN MECHANICAL AND TRIBOLOGY TEST INSTRUMENTATION
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A normal-load sensor provides feedback to the vertical motion controller, actively adjusting the sample position to ensure a constant load during testing. The tester has fully automated PC-based motor-control and data-acquisition, with a user-friendly proprietary software system in a Windows 2000/XP multitasking environment. The test data can be acquired, calculated and displayed in real time, as well as stored for future retrieval.
Hardware Description
2.1 The Basic System The basic UMT system consists of the Control Unit and the Testing Unit. The Control Unit uses a Pentium based computer with 16 channels of data acquisition and 2 or 3 computerized motor controllers depending on options. It includes a 17 LCD Monitor, keyboard, and mouse. It comes with CETR control software and a Windows 2000/XP Operating System. Description of the control software is covered in the UMT Software Operating Manual. The Testing Unit has a high density cast iron vibration-dampened frame. The upper selection of the Testing Unit has both vertical and lateral positioning systems to control the location and loading force of the upper test specimen. The upper specimen vertical positioning system is motorized and has one of three different resolution position encoders. Vertical positioning system: Maximum Travel: up to 150 mm. Speed: 0.001 to 10 mm/s. Position Resolution: Basic encoder: 1 micron High resolution encoder: 0.1 micron Ultra-High resolution encoder: 50 nm (500 Angstroms) The upper specimen lateral positioning system may have motorized or manual control. The motorized version has a position encoder, and the manual version uses a micrometer. Lateral positioning system: Maximum Travel: 75 mm Motor controlled with encoder: Position Resolution: 2 micron Speed: 0.01 to 10 mm/s. Manual: Position Resolution: 0.5 mm 15 YEARS OF LEADERSHIP IN MECHANICAL AND TRIBOLOGY TEST INSTRUMENTATION
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The Testing Unit also includes a power driver for the lower specimen drives, a 2-channel signal conditioner for Load and Friction, and up to 6 additional input channels for advanced sensors. A built-in temperature controller is optional. The picture shows the basic Testing Unit without additional components. The drive motor for the carriage is hidden in the top. The lateral positioning system is mounted to the carriage and can be seen at the center of the picture The base of the Testing Unit has a fixture in the shape of a ring for mounting and leveling various drives for the lower test specimen.
2.2 Typical Configuration When additional components are added to the basic system to perform a particular type of tribology study such as Pin-on-Disk the tester configuration may be as follows: The vertical carriage stage is motor driven with an encoder for position feedback. It provides the loading force for pressing the upper specimen (in this example a pin) against the lower specimen (in this example a disk). The lateral positioning stage may or may not be motorized. It is mounted to the carriage and is used to offset the upper specimen from the center axis. In this case it would set the radius at which the pin touches the disk. The 2D force sensor assembly mounts either directly to the lateral positioning stage or to an extension block which in turn mounts to the lateral positioning stage. It senses the vertical or loading force and the lateral drag or friction force. The loading force sensor is used as feedback for the vertical carriage positioning system to maintain a constant loading force. The combination of loading force and friction are used to calculate the coefficient of friction. If this where a disk-on-disk study a 6D force sensor would be used in stead of the 2D force sensor in order to measure torque. Mounted to the force sensor is a suspension which allows the upper specimen to follow variations in the height of the lower specimen as it rotates. The maximum load rating of the suspension should match the maximum range of the force sensor.
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The upper specimen holder mounts to the suspension, and the upper specimen is held in the holder. In this example the holder would be a collet chuck, and the upper specimen would be a needle-tipped pin. The lower specimen is held by the lower specimen holder. In this example the holder would be the specimen table which is part of the rotational motor drive, and the lower specimen would be a disk. The rotational motor drive is chosen on the basis of the speed and torque requirements of the test. In addition to rotational motor drives there is a reciprocating motion drive and a block-onring drive. The lower specimen drives are attached to the drive base which has adjustments for leveling the lower drive.
3 UMT System Installation and Setup This section will cover system installation, setup and initial checkout
3.1 Unpacking the system On receipt, inspect the boxes for signs of mishandling. Note any damage on the bill of lading. Also note the condition of the Shock Watch and Tip-n-Tell indicators. Open all the boxes and verify that the contents are undamaged. If any damage is found, immediately file a claim with the carrier (shipping company) for damages and notify CETR as to the type and extent of damage. Check the contents of the boxes to verify that all ordered items have been received, all cables and adapters are present and all ordered options are installed or included. Notify CETR immediately of any discrepancies. Remove the equipment from the box(es) and place on a level, solid table or workbench. 3.2 Connecting the System Connect power cords to the Control Unit, monitor and Testing Unit. Connect the display to the monitor connector on the back of the Control Unit. Connect the mouse and keyboard to their connectors on the back of the Control Unit.
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Connect the cable that has 37 pin connectors on both ends to the matching connector on the back of the Control Unit and the Testing Unit. This cable is for motor control signals. Connect the cable that has 25 pin connectors on both ends to the matching connector on the back of the Control Unit and the Testing Unit. This cable is for data acquisition.
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3.2.1
Installing Components
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3.2.2
Force Sensors
Several different Friction/Load Sensors varying in range and sensitivity are available for the UMT system. The Friction/Load Sensor mounts either directly to the slider (lateral positioning stage) or to a 2 or 4 extension block, which in turn mounts to the slider. A manually operated y-axis positioning stage may also be mounted to the slider. The sensor should be mounted with the connector on the left when friction force (Fx) is to be sensed from front to back such as pin on disk testing. When the slider is used to move the specimen left and right against a stationary lower specimen the sensor should be mounted with the connector facing forward. Connect the flat cable from the left side of the Instrumentation Electronics Enclosure to the Friction/Load Sensor. In some cases it may be necessary to use an extension cable. Dual-beam sensors have threaded holes on the sensing surface for mounting suspensions and adapters.
3.2.2.1 2-D Force Sensors The two dimensional force sensors are used to measure the sliding and breakaway friction force between the upper and lower test specimens as well as measuring and controlling the loading force. Model numbers range from FVL (Very Low) to DFH-100 (High). Force sensors with a full scale range of 50 g or less have a small square hole in the bottom for mounting a suspension which is held in place by a screw. Higher force sensors have a plate with threaded hole for mounting suspensions and specimen holders.
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2-Dimensional Force Sensors Specifications Model FVL FL DFM-0.5 DFM-1 DFM-2 DFH-5 DFH-10 DFH-20 DFH-50 DFH-100 Range: 1 to 100 mN (0.1 to 10 g) 5 to 500 mN (0.5 to 50 g) 0.05 to 5 N (5 to 500 g) 0.1 to 10 N (10 g to 1 kg) 0.2 to 20 N (20 g to 2 kg) 0.5 to 50 N (50g to 5 kg) 1 to 100 N (0.1 to 10 kg) 2 to 200 N (0.2 to 20 kg) 5 to 500 N (0.5 to 50 kg) 10 to 1,000 N (1 to 100 kg) Resolution: 10 N (1 mg) 50 N (5 mg) 0.25 mN (25 mg) 0.5 mN (50 mg) 1 mN (100 mg) 2.5 mN (0.25 g) 5 mN (0.5 g) 10 mN (1.0 g) 25 mN (2.5 g) 50 mN (5.0 g)
Models FVL/FL
Models DFM/DFH
Above are bottom views of 2-D Force Sensors. The one on the left is typical of sensors with a full scale of 50 g or less. There is a square hole in the round recess. A matching suspension mounts in this hole and is held in place by the screw seen on the side near the mounting hole. The force sensor on the right represents sensors with a full scale of 0.5 kg or more. A suspension or a specimen holder mounts onto the plate with threaded holes.
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3.2.2.2 6D Torque/Force Sensors The 6 dimensional toque/force sensors are used to measure torque and force in the x, y, and z axis. (Tx, Ty, Tz, Fx, Fy, Fz) 6-Dimensional Force/Torque Sensors Specifications
Model TL-2 Range 0.6 to 125 N*mm 0.2 to 20 N (0.02 to 2 kg) 0.1 to 10 N (0.01 to 1 kg) 1.2 to 250 N*mm 0.4 to 40 N (0.04 to 4 kg) 0.2 to 20 N (0.02 to 2 kg) 5 to 1000 N*mm 0.5 to 60 N (0.05 to 6 kg) 0.2 to 20 N (0.02 to 2 kg) 10 to 2000 N*mm 1.5 to 120 N (0.15 to 12 kg) 0.4 to 40 N (0.04 to 4 kg) 20 to 4000 N*mm 2 to 240 N (0.2 to 24 kg) 0.8 to 80 N (0.08 to 8 kg) 50 to 10,000 N*mm 5 to 580 N (0.5 to 58 kg) 1.9 to 190 N (0.19 to 19 kg) 100 to 20,000 N*mm 10 to 1160 N (1.0 to 116 kg) 5.8 to 580 N (0.58 to 58 kg) Resolution 15 mN*mm 2.5 mN 1.2 mN 30 mN*mm 5 mN 2.5 mN 125 mN*mm 7.5 mN 2.5 mN 250 mN*mm 15 mN 5 mN 500 mN*mm 30 mN 10 mN 1.25 N*mm 65 mN 20 mN 2.5 N*mm 135 mN 65 mN
TM-4
TH-6
TH-12
TH-24
TH-50
TH-100
Torque: Load: Friction/Lateral Force: Torque: Load: Friction/Lateral Force: Torque: Load: Friction/Lateral Force: Torque: Load: Friction/Lateral Force: Torque: Load: Friction/Lateral Force: Torque: Load: Friction/Lateral Force: Torque: Load: Friction/Lateral Force:
Models TL/TH
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3.2.3
Suspensions, Adapters, and Upper Specimen Holders
There are many types of upper specimen holders available for holding balls, pins, needles, micro- cutting blades, etc. The specimen holders can be divided into three groups - those with 0.13 square or round shafts, 0.25 round shafts, and those with 0.5 round shafts. The chart below shows the relationship between the different components. For example, follow the column on the left side of the chart. The model FL sensor can accept a suspension with a 0.13 square shaft. That suspension can accept any specimen holder with a 0.13 square or round shaft. When no suspension is needed, the specimen holder can attach directly to the sensor. For another example, a model DFH sensor can accept a matching suspension with a rigid adapter, or it can accept the rigid adapter directly. That rigid adapter can accept any specimen holder with a 0.5 shaft or a clamping adapter for smaller size shafts.
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3.2.4 Changing Friction/Load Sensors When replacing a Friction/Load Sensor with one that has a different range, it is necessary to change the settings for both Fx and Fz in the Options file. The Scale should be set to full scale for the corresponding Units. The Warn threshold should be set to a level just below full scale, and the Abort threshold should be set to the full scale level. Please refer to the Software Operating Manual for more detailed description.
3.2.5 Force Mounting Extension Blocks Force sensor mounting extension blocks are installed between the lateral positioning stage on the carriage and the force sensor. 2 Mounting Block This block is used to lower the force sensor assembly by 2. This shifts the range of the vertical positioning carriage by 2 inches. 4 Mounting Block This block is used to lower the force sensor assembly by 4. This shifts the range of the vertical positioning carriage by 4 inches. 0.5 Y-direction Positioning Attachment This is a micro-positioning stage that allows movement of the upper specimen in the Y direction (front to back). It is manually positioned with a built-in micrometer adjustment.
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0.5 Y-direction Positioning Attachment
3.2.6
Lower Specimen Motorized Drives and Tables
Several different Lower Specimen Motorized Drives and Tables may have been purchased with the UMT system varying in type of motion and torque rating. There are four types of drives: rotational, block-on-ring, linear Y stage, and reciprocating. All drives have a base which matches the lower drive mounting ring located in the base of the Testing Unit. Drives should be installed with the cables on the right so that they can be connected to the Testing Unit connectors which are located in the lower right corner.
3.2.6.1 Rotational Motion Drives with Specimen Table, with or without encoder The table below lists six different drives that rotate the specimen about a vertical axis.
Model Number with/without Encoder S25UE/S25U0 S20HE/ S20H0 S21ME/ S21M0 S24LE/ S24L0 S33HE S35ME Drive Type Low-Cost Low-Torque Ultra-Low Speed Medium-Torque Low-Torque High-Torque Medium-Torque Max RPM 5000 30 1000 4000 3000 5000 Maximum Load 0.5 kg 100 kg 20 kg 20 kg 100 kg 60 kg Acc/Dec Time Sec. 5 5 5 5 5 5 Encoder Resolution 4000 240000 8000 2000 10000 6400
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Model S25UE
Model S20HE
Models S21ME/S24LE
Models S33HE/S35ME
3.2.6.2 Reciprocating Motion Drives: These drives move the specimen in linear fashion.
Model Number with/without Encoder R23ME/ R23M0 R35HE Drive Type Fast-Oscillating Fast-Oscillating, Integrated Lateral Sensors Precision Positioning, Slow Reciprocating Precision Positioning, Medium Reciprocating Max Freq/Speed 40 Hz 60 Hz 10 mm/sec 100 mm/sec Maximum Load 25 kg 100 kg Acc/Dec Time Sec. 5 5 Encoder Resolution 4000 8000
L20HE
100 kg
0.1
4000
L25HE
100 kg
0.1
2000
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Model R23ME
Model R35HE with Integrated Lateral Sensors
Model L20HE
Model L25HE
3.2.6.3 Block-On-Ring Drives: These drives rotate the lower specimen about a horizontal axis.
Model Number with/without Encoder B21ME/ B21M0 B24LE/ B24L0 B33HE B35ME Drive Type Medium-Torque Low-Torque High-Torque, Integrated Lateral Sensors Medium-Torque, Integrated Lateral Sensors Max RPM 1000 4000 3000 5000 Maximum Load 30 kg 12 kg 100 kg 60 kg Acc/Dec Time Sec. 5 5 5 5 Encoder Resolution 8000 2000 10000 6400
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Models B21ME/B24LE
Models B33HE/B35ME with Integrated Lateral Sensors
3.2.6.4 Changing Lower Specimen Drives When replacing a lower specimen drive with a different type it is necessary to change the settings in the Options file. Click on Options in the Tool Bar. If an options file has been previously saved with the settings for current drive and force/load sensor, click on Load and select the saved file. Please refer to the Software Operating Manual for more detailed description. 3.2.7 Additional Sensors In addition to the friction /load sensors there may be other sensors used with the UMT such as Acoustic Emission (AE), Temperature, and Electrical Contact Resistance (ECR). These sensors plug into their matching amplifiers located in the Instrumentation Electronics Enclosure. For example, the Acoustic Emission sensor cable plugs through the hole that is labeled AE on the front of the enclosure. 3.2.7.1 Electrical Contact Resistance Measurement and Recording option These sensors measure the electrical resistance in ohms between the upper and lower specimens. The choice of sensor depends on the conductivity or insulation characteristics of the test specimens. Model: ECR-0.5 ECR-1 ECR-1K ECR-100K ECR-1M Range: 0.005 to 0.5 Ohm 0.010 to 1.0 Ohm 10 to 1000 Ohm 1 kOhm to 100 kOhm 10 kOhm to 1 MOhm
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Holders for the above measurement modules:
Wire Probe Holder
Solid (Ball) Holder
3.2.7.2 Temperature Measurement and Recording Model

Model Range TMR-150 -50 C to 150 C (-60 F to 300F) TMR-350 0 C to 350 C (32 F to 660F) TMR-1000 0 C to 1000 C (32 F to 1830F) Sensor Model RTD-150 RTD-350 TC-1000
Temperature Sensors:
Platinum RTD for up to 350 C High stability thermocouple for up to 1000 C
Lower Specimen Elevated Temperature Control Each of the different types of lower specimen drive requires its own heating chamber if elevated temperature is to be utilized. Listed below are the different types of chambers. Drive Type Rotational Rotational Rotational Reciprocating Reciprocating Block-On-Ring Temperature Range Up to 150 C Up to 300 C Up to 1000 C Up to150 C Up to 1000 C Up to 150 C Liquid/ Grease Holder Yes Yes No Yes No Yes
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Stand-Alone Temperature Controller The Stand-Alone Temperature Controller is for systems originally purchased without a built-in controller. It has a temperature range from ambient to 1000 C. 3.2.7.3 DC Voltage Measurement and Recording Model VMR-3 Range: -3 to +3 VDC, Resolution: 5mV 3.2.7.4 Contact Acoustic Emission (AE) Detector Model AE-5 Frequency response: 0.2 to 5 MHz 3.2.8 Upper Specimen Suspensions In order to maintain a constant load it is sometimes necessary to have a suspension between the force sensor assembly and the upper specimen holder. Suspensions are spring devices used to compensate for variations in the distance between the force sensors and the surface of the lower specimen when the lower specimen is in motion. Even though the carriage will automatically move up and down to maintain a constant average load, it can only respond to low frequency variations, therefore may require the use of a suspension to make up the difference. Suspensions are available in a range of stiffness from 50 grams to 100 kilograms. The choice of suspension should match the sensitivity of the force sensor. Suspensions with a full scale range of 50 g have a small square shaft at the upper end for mounting to the bottom of the force sensor and a matching hole at the bottom end to accept an upper specimen holder. Medium and high range suspensions have a plate at the top that attaches to the bottom plate of the force sensor.
Suspension for sensor model FL
Suspension for sensor model DFM
Suspension for sensor model DFH 15 YEARS OF LEADERSHIP IN MECHANICAL AND TRIBOLOGY TEST INSTRUMENTATION
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3.2.9
Upper Specimens and Specimen Holders Needle-Tipped Pins Balls and Ball Holder Diamond Stylus and Holder Micro-Cutting Blades and Holder Self-Adjusting Ball-Joint Holder
3.2.10 Lower Specimens and Specimen Holders Stainless Steel Discs Lapping Discs with Alumina Abrasives and Polyester Back Block-On-Ring Specimens
3.2.11 Specialized Holders and Specimens
Holder for Disk-on-Disk test mode
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3.3 Preliminary Mechanical and Electrical Checkout Verify all the connections to the units and power up the Testing Unit, PC, and display. Click on the UMT icon to display the main screen.
3.3.1 Motorized specimens check This procedure performs a basic functional check of the drives. Click on the Semi-automatic Panel button on the Tool bar. Click on the Carriage tab and enter the settings as shown. Click on the Run button and the carriage should move down 10 mm in10 seconds and stop. While the carriage is moving the green light should be lit and the red light off. Change the setting to Up and click on the Run button. The carriage should move up 10 mm in 10 seconds.
Click on the Spindle tab and enter the settings as shown. Click on the Run button and the lower drive should rotate 1 turn clockwise in 6 seconds and stop. While the drive is moving the green light should be lit and the red light off. Change the setting to Counter Clockwise and click on the Run button. The drive should rotate 1 turn counterclockwise in 6 seconds and stop. If the lower drive is a reciprocating drive then 1 rotation of the drive will cause the specimen table to move 1 full stroke. If the UMT has an upper rotational motion drive, click on the Spindle II tab, and perform the same test as above.
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If the UMT has motorized lateral positioning, click on the Slider tab, and enter the settings as shown. Click on the Run button, and the slider should move left 10 mm in10 seconds and stop. While the slider is moving the green light should be lit and the red light off. Change the setting to Right, and click on the Run button. The slider should move right 10 mm in 10 seconds.
3.3.2 Instrument check This procedure performs a basic functional check of the sensors. A suspension should be mounted to the sensor before doing the following test. Click on the Automatic Panel button on the Tool bar. 3.3.2.1 Force/Load Sensors The screen that appears is displaying a real time plot of the force/load sensor output. The white trace displays the z-axis or loading force. The red trace displays the x-axis or fiction force. Both traces should be close to zero on the y-axis. Pulling downward on the suspension should move the white trace upward. Likewise, pushing up on the suspension should move the white trace downward. Pulling forward on the suspension should move the red trace downward. Likewise, pushing back on the suspension should move the red trace upward.
Note: The trace colors may differ depending on the Graphs settings 15 YEARS OF LEADERSHIP IN MECHANICAL AND TRIBOLOGY TEST INSTRUMENTATION
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If you do not get the above results check to make sure all connections are properly made. A large offset from zero or no response to pulling or pushing could indicate a damage force/load sensor. In this case contact CETR Customer service at the number at the back of this manual. 3.3.2.2 Acoustic Emission Sensor Click on the Automatic Panel button on the Tool bar again.
The above Edit Options screen will appear. Select the Contact Acoustic Emission (AE) option under Topics (if available). Click on the OK button. The screen that appears displays a real time plot of the AE sensor output. The trace should be close to zero on the y-axis.
Tap the AE sensor lightly against the body of the tester. Pulses should appear on the real time trace.
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3.3.2.3 Electrical Contact Resistance Sensor Click on the Automatic Panel button on the Tool bar again.
The above Edit Options screen will appear. If your tester has the Electrical Contact Resistance (ECR) option, select it under Topics. Click on the OK button. In this example the model ECR-1K is installed. It measures resistance from 0 to 1000 ohms. The screen that appears is displaying a real time plot of the ECR sensor output. The trace should be at the top when the leads are not connected to anything. When the leads are held together the trace should go to zero. If a resistor is available in the range from 100 to 900 ohms, or whatever range your ECR model can measure, connect the leads to each end of the resistor. The trace should be at the corresponding level on the y-axis.
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Typical Test Procedures
4.1 Ball/Pin-on-Disk Friction Test

4.1.1 Ball/Pin-on-Disk System Setup This test method involves a ball shaped upper specimen that slides against a rotating disk as a lower specimen under a prescribed set of conditions. The UMT allows for monitoring during the test the actual dynamic normal load, friction force and friction coefficient, and depth of wear. Optionally, it can measure additional parameters of contact acoustic emission, electrical contact resistance, and temperature. The configuration below is an example of one of many possible combinations of friction/load sensor, rotational drive, specimen holder, and specimens. Hardware Configuration: 4 Mounting Block Model DFH-5 Dual Friction/Load Sensor - range 0.5 N to 50 N Spring Suspension 3/8 Ball Holder - for sensors mod. DFH 440-C Stainless Steel Ball, Dia. 3/8 Stainless Steel Disk Medium Torque Rotation Drive - Mod. S21ME or S33HE Optional Additional Sensors - mod AE-5 Acoustic Emissions Sensor - mod ECR-xx Electrical Contact Resistance - mod. TMR-150 Temperature Measurement & Recording
Data Collection: The following should be checked under DataFile: Fx Friction Force Fz Normal Force T Time Z1 Carriage Position (used to determine Wear Depth) Te Temperature (optional) AE Acoustic Emission (optional) EC Electrical Contact Resistance (optional)
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4.1.2
Ball/Pin-on-Disk Test Script Parameters
The test schematic is shown in Figure 4.1. The friction test using ball or pin-on-disk mode can be achieved using a test script with two sequences: initial loading with 1 step and Friction test with 1 step. The test script parameters are described below:
Force sensor
Pin Holder Pin Disk
Suspension
Fig. 4.1 Schematic of UMT Pin-on-Disk test set-up
TEST SEQUENCE-1: Engage > Test > Disengage > Data File> Sequence Note > Touch Force: -0.5N; Pretouch:0.3; Touch: 0.1;Tracking: 0.005mm/s Tolerance (N): Positive 0.01; Negative 0.01 Z-carriage Retracting Distance: 0 mm; Velocity : 0 mm/s. Uncheck 'Create data file'; No data recording Initial Loading
STEP 1: //To apply load// General > Carriage > Spindle > Slider > Controlled: Carriage/Load; Step: Constant Force(Fz); Duration: 10 s. Force: -20 N Move: Continuous; Velocity: 0 rpm Position: Idle
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TEST SEQUENCE-2: Engage > Test > Disengage > Data File> Touch Force: -0.5N; Pretouch: 0.3; Touch: 0.1; Tracking: 0.005mm/s Tolerance (N): Positive 0.01; Negative 0.01 Z-carriage Retracting Distance: 5 mm; Velocity : 8 mm/s. File name: give suitable file name such as C:\Trib\Test\....... Check 'Create data file'; Check Fx, Fz, and T (time) channels. Filter width: 10 samples Sequence Note > Friction Test
STEP 1: //To apply load and rotate the spindle cyclically// General > Carriage > Spindle > Slider > Controlled: Carriage/Load; Step: Constant Force(Fz); Duration: 120 s. Force: -20 N Move: increment; Velocity: 50 rpm; Distance: 10 rev; Direction: Cycle Position: Idle
IMPORTANT NOTE: The above script is an example of Friction test with a constant load of 20 N assuming that a 50 N (5 kg) force sensor is installed in UMT. The unit of force is in Newton. If your UMT option file has a different unit of force (Fz and Fx), change the force values in the script accordingly. Make sure sensor protection in options is on. You can check it by clicking Options>Edit>Channels>Fz>check warn if absolute value exceeds... and check abort if absolute value exceeds. The force values for warn and abort actions are to be set at a little less than the full scale. Repeat the sensor protection check for Fx channel. Such sensor protection checks are necessary to avoid damaging the sensor. The engage parameters may slightly vary from one system to other because of variation in system stiffness. After the test, open the test data (.tst) file with UMT Viewer, Check Fx channel and click on the Symmetry ] . The Fx should be symmetrical along Fx = 0 line. Then check the COF channel button [ and COF will be displayed as a function of test time. If the original Fx plot is asymmetrical to an extent that is more than 20% of the maximum Fx, contact the CETR customer service.
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4.2 Stribeck Test

4.2.1 Stribeck Test System Setup
The test schematic with ball-on-disk test mode is shown in Figure 4.2. It requires a rotary drive, a special lube holder with oil splash protection cover, a ball holder, a ball, a clean disk, and lubricant. The test to obtain Stribeck curves of the lubricant may performed using a script with two sequences: run-in with 5 steps and Stribeck test with 12 steps. The test script parameters are described below in details:
Fig. 4.2 Schematic UMT Stribeck test set-up
4.2.2
Stribeck Test Script Parameters
TEST SEQUENCE-1: Engage > Test > Disengage > Data File> Touch Force: -0.1N; Pretouch: 1.0; Touch: 0.1; Tracking: 0.01mm/s Tolerance (N): Positive 0.005; Negative 0.005 Z-carriage Retracting Distance: 0 mm; Velocity: 0 mm/s. File name: give suitable file name such as C:\Trib\Test\....... Check 'Create data file'; Check Fx, Fz, and T (time) channels. Filter width: 10 samples Sequence Note > Run-in STEP 1: //To apply load// Controlled: Carriage/Load; Step: Constant Force(Fz); Duration: 5 s. Force: -4 N Move: Continuous; Velocity: 0 rpm Position: Idle 15 YEARS OF LEADERSHIP IN MECHANICAL AND TRIBOLOGY TEST INSTRUMENTATION Page 30 General > Carriage > Spindle > Slider >
STEP 2: //To perform initial run-in at 50 rpm cyclically for 60 min// General > Carriage > Spindle > Slider > Controlled: Carriage/Load; Step: Constant Force(Fz); Duration: 60 min. Force: -4 N Move: increment; Velocity: 50 rpm; Distance: 100 rev; Direction: Cycle Position: Idle
STEP 3: //To stop rotation of spindle without lifting the ball// General > Carriage > Spindle > Slider > Controlled: Carriage/Load; Step: Constant Force(Fz); Duration: 15 s. Force: -4 N Move: Continuous; Velocity: 0 rpm Position: Idle
STEP 4: //To perform run-in at 600 rpm cyclically for 15 min// General > Carriage > Spindle > Slider > Controlled: Carriage/Load; Step: Constant Force(Fz); Duration: 15 min. Force: -4 N Move: increment; Velocity: 600 rpm; Distance: 300 rev; Direction: Cycle Position: Idle
STEP 5: //To stop rotation of spindle without lifting the ball// General > Carriage > Spindle > Slider > Controlled: Carriage/Load; Step: Constant Force(Fz); Duration: 15 s. Force: -4 N Move: Continuous; Velocity: 0 rpm Position: Idle
TEST SEQUENCE-2: Engage > Test > Disengage > Data File> Touch Force: -0.1N; Pretouch: 1.0; Touch: 0.1; Tracking: 0.01 mm/s Tolerance (N): Positive 0.005; Negative 0.005 Z-carriage Retracting Distance: 10 mm; Velocity: 8 mm/s. File name: give suitable file name such as C:\Trib\Test\....... Check 'Create data file'; Check Fx, Fz, and T (time) channels. Filter width: 100 samples Sequence Note > Stribeck Test
STEP 1: //To perform Stribeck at 2000 rpm cyclically for 2 min// General > Carriage > Spindle > Slider > Controlled: Carriage/Load; Step: Constant Force(Fz); Duration: 2 min. Force: -4 N Move: increment; Velocity: 2000 rpm; Distance: 200 rev; Direction: Cycle Position: Idle
STEP 2: //To perform Stribeck at 1500 rpm cyclically for 2 min// General > Carriage > Spindle > Slider > Controlled: Carriage/Load; Step: Constant Force(Fz); Duration: 2 min. Force: -4 N Move: increment; Velocity: 1500 rpm; Distance: 150 rev; Direction: Cycle Position: Idle Page 31
STEP 9: //To perform Stribeck at 10 rpm cyclically for 2 min// General > Carriage > Spindle > Slider > Controlled: Carriage/Load; Step: Constant Force(Fz); Duration: 2 min. Force: -4 N Move: increment; Velocity: 10 rpm; Distance: 1 rev; Direction: Cycle Position: Idle Page 32
STEP 10: //To perform Stribeck at 5 rpm cyclically for 2 min// General > Carriage > Spindle > Slider > Controlled: Carriage/Load; Step: Constant Force(Fz); Duration: 2 min. Force: -4 N Move: increment; Velocity: 5 rpm; Distance: 0.5 rev; Direction: Cycle Position: Idle
IMPORTANT NOTE: The above script is an example of Stribeck test with a constant load of 4 N assuming that a 5 N (500g) force sensor is installed in UMT. The unit of force is in Newton. If your UMT option file has a different unit of force (Fz and Fx), change the force values in the script accordingly. Make sure sensor protection in options is on. You can check it by clicking Options>Edit>Channels>Fz>check warn if absolute value exceeds... and check abort if absolute value exceeds. The force values for warn and abort actions are to be set at a little less than the full scale. Repeat the sensor protection check for Fx channel. Such sensor protection checks are necessary to avoid damaging the force sensor. The engage parameters may slightly vary from one system to other because of variation in system stiffness. After the test, open the Stribeck test data (.tst) file with UMT Viewer, Check Fx channel for first step and click ) button. The Fx should be symmetrical along Fx = 0 line. Repeat such the symmetry ( process of making Fx symmetric for all the 12 steps. Then click on Result Graph button [ ] and the Stribeck curve will be displayed. If required, choose the x-axis parameters. If the original Fx plot is asymmetrical to an extent that is more than 20% of the maximum Fx, contact the CETR customer service.
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4.3 Ball/Pin-on-Flat Reciprocating Wear Test

4.3.1 Ball/Pin-on-Flat Wear Test System Setup This test method utilizes a ball upper specimen that slides against a flat lower specimen in a linear, back and forth sliding motion, under a prescribed set of conditions. The load is applied downward through the ball specimen against the flat specimen mounted on a reciprocating drive. Hardware Configuration: 4 Mounting Block Model DFH-5 Dual Friction/Load Sensor - range 0.5 N to 50 N Spring Suspension 3/8 Ball Holder for sensors mod. DFH 3/8 Diameter Ball Specimen Lower Linear Reciprocating Motion Drive - mod. R23ME or R35HE Optional Additional Sensors - mod. ECR-xx Electrical Contact Resistance - mod. TMR-150 Temperature Measurement & Recording
Data Collection: The following should be checked under Data File: Fx Friction Force Fz Normal Force T Time Z1 Carriage Position (used to determine Wear Depth) Te Temperature (optional) AE Acoustic Emission (optional) EC Electrical Contact Resistance (optional)
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4.3.2
Ball/Pin-on-Flat Wear Test Script Parameters
The test schematic is shown in Figure 4.3. The wear test using ball or pin-on-flat mode can be achieved using a test script with two sequences: initial loading with 1 step and Friction test with 1 step. The test script parameters are described below:
Force sensor
Pin Holder Flat plate
Fig. 4.3 Schematic of UMT-3 Pin-on-Flat test set-up
TEST SEQUENCE-1: Engage > Test > Disengage > Data File> Sequence Note > Touch Force: -0.5N; Pretouch:0.3; Touch: 0.1;Tracking: 0.005mm/s Tolerance (N): Positive 0.01; Negative 0.01 Z-carriage Retracting Distance: 0 mm; Velocity : 0 mm/s. Uncheck 'Create data file'; No data recording Initial Loading
STEP 1: //To apply load// General > Carriage > Reciprocating > Slider > Controlled: Carriage/Load; Step: Constant Force(Fz); Duration: 10 s. Force: -20 N Move: Continuous; Velocity: 0 rpm Position: Idle Page 35
TEST SEQUENCE-2: Engage > Test > Disengage > Data File> Touch Force: -0.5N; Pretouch: 0.3; Touch: 0.1; Tracking: 0.005mm/s Tolerance (N): Positive 0.01; Negative 0.01 Z-carriage Retracting Distance: 5 mm; Velocity : 8 mm/s. File name: give suitable file name such as C:\Trib\Test\....... Check 'Create data file'; Check Fx, Fz, and T (time) channels. Filter width: 10 samples Sequence Note > Wear Test
STEP 1: //To apply load and move the lower stage linearly// General > Controlled: Carriage/Load; Step: Constant Force(Fz); Duration: 2 hrs. Carriage > Force: -20 N Reciprocating > Move: Continuous; Velocity: 60 rpm; Slider > Position: Idle
IMPORTANT NOTE: The above script is an example of a wear test with a constant load of 20 N assuming that a 50 N (5 kg) force sensor is installed in UMT. The unit of force is in Newton. If your UMT option file has a different unit of force (Fz and Fx), change the force values in the script accordingly. Make sure sensor protection in options is on. You can check it by clicking Options>Edit>Channels>Fz>check warn if absolute value exceeds... and check abort if absolute value exceeds. The force values for warn and abort actions are to be set at a little less than the full scale. Repeat the sensor protection check for Fx channel. Such sensor protection checks are necessary to avoid damaging the sensor. The engage parameters may slightly vary from one system to other because of variation in system stiffness. After the test, open the test data (.tst) file with UMT Viewer, Check Fx channel and click on the Symmetry button [ ] . The Fx should be symmetrical along Fx = 0 line. Then check the COF channel and COF will be displayed as a function of test time. If the original Fx plot is asymmetrical to an extent that is more than 20% of the maximum Fx, contact the CETR customer service.
4.4 Block-on-Ring Test

4.4.1 Block-on-Ring Test System Setup
This test method covers the evaluation of wear and durability of lubricants and coatings under oscillating motion using a Block-on-Ring lower drive. A coated steel test ring (lower specimen) of a 35-mm diameter and 8.15-mm width is assembled on the tapered arbor of the Block-on-Ring drive. A steel test block (upper specimen) of 15.75-mm length and 6.35-mm width is held in the block holder. The ring is oscillated at a speed of 87.5 1 cycle/min around its axis in a 90 arc. In the beginning of the test, the specimens are worn-in under a small load; the main test is performed under the test load. The main test includes friction force measurements during the test, and then evaluates the wear life as a number of cycles required for the frictional force to rise to a predetermined value. 15 YEARS OF LEADERSHIP IN MECHANICAL AND TRIBOLOGY TEST INSTRUMENTATION
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In-situ measurement of wear depth is taken, and the wear after the test is evaluated by measuring the width of a wear scar on the test block.
The UMT allows for monitoring during the test the actual dynamic normal load, friction force and friction coefficient, and depth of wear. Optionally, it can measure additional parameters of contact acoustic emission and temperature.
UMT Hardware Configuration: 4 Mounting Block Model DFH-50 Dual Friction/Load Sensor - range 5 to 500 N Upper Specimen Holder for Blocks - for sensors mod. DFH Upper Specimen Test Block Lower Block-on-Ring Drive - mod. B21ME or B33HE Lower Specimen Test Ring Optional Additional Sensors - mod. AE-5 Contact Acoustic Emission Detector - mod. TMR-150 Temperature Measurement & Recording
Force sensor
Spring Suspension
Test Block
Test Ring
Data Collection: The following should be checked under DataFile: Fx Friction Force Fz Normal Force T Time Z1 Carriage Position (Used to determine Wear Depth) AE Acoustic Emission (optional) Te Temperature (optional)
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4.4.2
Block-on-Ring Test Script Parameters
TEST SEQUENCE-1: Engage > Test > Disengage > Data File> Sequence Note > Touch Force: -5N; Pretouch:0.3; Touch: 0.1;Tracking: 0.05mm/s Tolerance (N): Positive 0.1; Negative 0.1 Z-carriage Retracting Distance: 0 mm; Velocity : 0 mm/s. Uncheck 'Create data file'; No data recording Initial Loading
STEP 1: //To apply load// General > Carriage > Spindle > Slider > Controlled: Carriage/Load; Step: Constant Force(Fz); Duration: 10 s. Force: -100 N Move: Continuous; Velocity: 0 rpm Position: Idle
STEP 2: //Wear-in under smaller load// General > Carriage > Spindle > Slider > Controlled: Carriage/Load; Step: Constant Force(Fz); Duration: 1 min. Force: -100 N Move: Increment; Velocity: 7.96 revs/min; Distance 0.25 rev; Direction - cycle Position: Idle
TEST SEQUENCE-2: Engage > Test > Disengage > Data File> Touch Force: -5N; Pretouch: 0.3; Touch: 0.1; Tracking: 0.05mm/s Tolerance (N): Positive 0.1; Negative 0.1 Z-carriage Retracting Distance: 5 mm; Velocity : 8 mm/s. File name: give suitable file name such as C:\Trib\Test\....... Check 'Create data file'; Check Fx, Fz, and T (time) channels. Filter width: 10 samples Sequence Note > Wear Test
STEP 1: //To apply load and rotate the spindle cyclically// General > Carriage > Spindle > Slider > Controlled: Carriage/Load; Step: Constant Force(Fz); Duration: 5 hrs. Force: -300 N Move: Increment; Velocity: 7.96 revs/min; Distance 0.25 rev; Direction - cycle Position: Idle
IMPORTANT NOTE: The above script is an example of Friction test with a constant load of 300 N assuming that a 500 N (50 kg) force sensor is installed in UMT. The unit of force is in Newton. If your UMT option file has a different unit of force (Fz and Fx), change the force values in the script accordingly. Make sure sensor protection in options is on. You can check it by clicking Options>Edit>Channels>Fz>check warn if absolute value exceeds... and check abort if absolute value exceeds. The force values for warn and abort actions are to be set at a little less than the full scale. Repeat the sensor protection check for Fx channel. Such sensor protection checks are necessary to avoid damaging the sensor. The engage parameters may slightly vary from one system to other because of variation in system stiffness. After the test, 15 YEARS OF LEADERSHIP IN MECHANICAL AND TRIBOLOGY TEST INSTRUMENTATION Page 38
open the test data (.tst) file with UMT Viewer, Check Fx channel and click on the Symmetry button [ ] . The Fx should be symmetrical along Fx = 0 line. Then check the COF channel and COF will be displayed as a function of test time. If the original Fx plot is asymmetrical to an extent that is more than 20% of the maximum Fx, contact the CETR customer service.
4.5 Micro-Scratch Test

4.5.1 Micro-Scratch Test System Setup
The schematic of the setup used in this study is shown below. It can provide rotational, translational, or reciprocating motions with speeds ranging from 0.1 m/s up to 10 m/s. The load is applied to the sample by the carriage using Fz for a close-loop feed-back mechanism for stability and accuracy, and can be kept constant or linearly increasing from as low as 0.5 mN (0.05 g) to as high as 1000 N. Friction force (Fx), normal load (Fz), electric contact resistance (ECR) and acoustic emission (AE) are measured and recorded at a total sampling rate of 20k Hz. Wear depth, electric capacitance and digital camera are also readily available. The configuration below is an example of one of many possible combinations of friction/load sensor, lower drive, specimen holder, and specimens. Hardware Configuration: 4 Mounting Block 2 Mounting Block Model DFH-20 Dual Friction/Load Sensor - range 0.2 N to 200 N Holder for Micro-Cutting Blade Micro-Cutting Blade with 0.4mm Tip Radius Lower linear Reciprocating Motion Drive - mod. R23ME Additional Sensors - mod AE-5 Acoustic Emissions Sensor - mod ECR-100K Electrical Contact Resistance
Data Collection: Fx Friction Force Fz Normal Force T Time ECR Electrical Contact Resistance (optional) AE Acoustic Emission (optional) COF Coefficient of Friction (calculated automatically)
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4.5.2
Micro-Scratch Test Script Parameters
The test schematic is shown in Figure 4.5.2. The script will have 1 Sequence with 3 Steps which will perform multiple scratches with 1 mm separation distance between two scratches, and a scratch length of 5 mm. Micro-scratch test may be performed with either a constant load or a linearly increasing load. Script parameters for performing such multiple micro-scratches using a linear drive for moving the sample during scratching, and using the slider for positioning, are shown below:
Fig. 4.5.2 Schematic of UMT Micro-scratch test set-up
4.5.2.1 Test script parameters for micro-scratch test with constant load
TEST SEQUENCE-1: Engage > Test > Disengage > Data File> Touch Force: -0.5N; Pretouch: 0.3; Touch: 0.1; Tracking: 0.005mm/s Tolerance (N): Positive 0.01; Negative 0.01 Z-carriage Retracting Distance: 5 mm; Velocity: 8 mm/s. File name: give suitable file name such as C:\Trib\Test\....... Check 'Create data file'; Check Fx, Fz, AE (if applicable) and T (time) channels. Filter width: 10 samples Sequence Note > Micro-scratching with constant load
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STEP 1: //To apply load// General > Carriage > Linear(spindle) > Slider > Controlled: Carriage/Load; Step: Constant Force(Fz); Duration: 10 s. Force: -10 N Distance: 0; Velocity: 0 Position: Idle
STEP 2: //To scratch by moving sample forward over 5 mm at 0.2 mm/s velocity// General > Carriage > Linear (spindle) > Slider > Controlled: Carriage/Load; Step: Constant Force(Fz); Duration: 25 s. Force: -10 N Move: increment; Distance: 5 mm; Velocity: 0.2 mm/s; Direction: Forward Position: Idle
STEP 3: //To lift up carriage and move left by 1 mm and move back sample by 5 mm // General > Carriage > Linear (spindle) > Slider > Controlled: Carriage/Position; Step: Increment Carriage Displacement; Duration: 2 s. Offset: 2 mm; Velocity: 8 mm/s; Direction: Up Move: Increment; Distance: 5 mm; Velocity: 5 mm/s; Direction: Backward Velocity: manual-working 1 mm/s; Direction: Left; Position: increment; Offset: 1 mm.
4.5.2.2 Test script parameters for micro-scratch test with linearly increasing load
TEST SEQUENCE-1: Engage > Test > Disengage > Data File> Touch Force: -0.5N; Pretouch: 0.3; Touch: 0.1; Tracking: 0.005mm/s Tolerance (N): Positive 0.01; Negative 0.01 Z-carriage Retracting Distance: 5 mm; Velocity : 8 mm/s. File name: give suitable file name such as C:\Trib\Test\....... Check 'Create data file'; Check Fx, Fz, AE (if applicable) and T (time) channels. Filter width: 10 samples Sequence Note > Multiple Micro-scratching
STEP 1: //To apply initial load// General > Carriage > Linear(spindle) > Slider > Controlled: Carriage/Load; Step: Constant Force(Fz); Duration: 10 s. Force: -2 N Distance: 0; Velocity: 0 Position: Idle
STEP 2: //To scratch by moving sample forward over 5 mm at 0.2 mm/s // General > Carriage > Linear (spindle) > Slider > Controlled: Carriage/Load; Step: Linear Force (Fz) by time; Duration: 25 s. Force From: -2 N; To: -10 N Move: increment; Distance: 5 mm; Velocity: 0.2 mm/s; Direction: Forward Position: Idle
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STEP 3: //To lift up carriage and move left by 1 mm and move back sample by 5 mm // General > Carriage > Linear (spindle) > Slider > Controlled: Carriage/Position; Step: Increment Carriage Displacement; Duration: 2 s. Offset: 2 mm; Velocity: 8 mm/s; Direction: Up Move: Increment; Distance: 5 mm; Velocity: 5 mm/s; Direction: Backward Velocity: manual-working 1 mm/s; Direction: Left; Position: increment; Offset: 1 mm .
IMPORTANT NOTE: The above two scripts are examples of micro-scratch tests with constant load of 10 N and linearly increasing load up to 10 N, assuming that a 200 N (20 kg) force sensor is installed in UMT. The unit of force is in Newton. If your UMT option file has a different unit of force (Fz and Fx), change the force values in the script accordingly. Make sure sensor protection in options is on. You can check it by clicking Options>Edit>Channels>Fz>check warn if absolute value exceeds... and check abort if absolute value exceeds. The force values for warn and abort actions are to be set at a little less than the full scale. Repeat the sensor protection check for Fx channel. Such sensor protection checks are necessary to avoid damaging the force sensor. Try the above script initially once and open the tst file in UMT Viewer. Look for the force profile (Fz), it should be stable (linear in case of linearly increasing) and it should reach the intended maximum force. If not, try again after changing the engage parameters. The engage parameters may slightly vary from one system to other because of variation in system stiffness. For multiple scratching, repeat the tests as many times as needed at the start of the test. 4.5.3 Typical Micro-Scratch Experimental Results:
The micro-blade was found to be the most effective counter surface for accelerate wear tests for hard films, as compared to a ball or pin geometry. The advantage for using micro-blade is not limited to this, as it is also a very effective way to evaluate delaminating of film coatings. The reason for choosing the micro-blade was based on the contact stress analysis. For spherical or cylindrical contact geometry, the contact stress is distributed well beyond a few nanometers (film thickness) deep. One really needs the contact stress concentrated within or near the surface film one wishes to study, rather than distributed well into the substrate/underlay, as in the case of ball or pin contact geometry. The test schematic of a micro-blade used for evaluating a few um thick DLC or Al2O3 coating on steel substrate is shown in Figure 4.5.3.
Figure 4.5.3 Schematic of Micro-blade set-up with Acoustic Sensor
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In the scratch test, as the micro-blade moving slowly against the film coating, progressive materials removal occurred as illustrated in the Viewer screenshot below. In this screenshot, the corresponding measured friction force (Fx) is red, the normal force (Fz) is white, electric contact resistance (ECR) is yellow, and acoustic emission (AE) is green. All the above channels are plotted as a function of testing time in seconds. Please note, the normal force increased with increasing testing time from 0 to 100 grams. The oxide coating film was progressively cut through by the micro-blade at about 22 seconds, corresponding to a critical load of about 40 grams. At this critical load, friction force was shifted to a higher value with a different slope. At exactly the same time, ECR dropped to practically zero, because the micro-blade made contact with the conductive magnetic film after cutting through the coating. Meanwhile, AE signal fluctuated much more strongly at the critical load. The screenshot below shows scratch test raw data for 3 um thick coating of Al2O3 on steel substrate.
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4.6 Micro-Indentation Test

4.6.1 Micro-Indentation System setup
Micro-Indentation tests can be performed using Rockwell indenter, Vickers indenter, diamond stylus (5 or 12 m tip radius) with a capacitance sensor. A micro indentation test schematic using a Vickers indenter is shown in Figure 4.5.1
Force Sensor
Suspension Reference plate Indenter Specimen Pin holder Capacitance probe holder
Fig. 4.6.1 UMT Micro-indentation test set-up
Mount the sample on the provided sample mounting. Different mounting techniques can be used to mount the sample to the sample mounting. The sample, if heavy, can be placed on the mounting under its own weight, or, if the sample is very flat and light, it can be glued to the mounting using wax. Move the lower linear drive (y-axis) towards the indenter using the keyboard: for macro positioning use Alt < or Alt > or for fine positioning use Ctrl < or Ctrl >. Make sure that there are no obstructions in the way. Move the linear drive till the sample comes directly under the indenter.
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Use the slider to move left or right and the capacitance sensor holder (can be rotated around vertical shaft, when the screw holding it is loosen) to position the indenter very close to the capacitance sensor in X direction. The capacitance sensor should be close to the indenter for optimum results. The capacitance sensor should be fully under the reference disk. After the x positioning is done, bring the indenter down slowly until it is very close to the sample surface (Use Ctrl + down arrow keys). Make sure during the motion the indenter or the reference disk doesnt hit the capacitance sensor/holder. If capacitance sensor holder/capacitance sensor is in the way, lower the capacitance sensor holder. When the indenter is very close to the surface (or barely touching the surface) move the capacitance sensor holder up (after loosening the screw). Bring the sensor within 220 230 microns to the reference disk by viewing the distance on the Capacitance graph and using a 200 micron shim provided. When the sensor is not in range it shows a full scale of 254 microns. The setup should schematically look like the following drawing:
Capacitor sensor Indenter
Indenter
Capacitor sensor Sample
Reference Disk
Reference disk Top View
Front View
Fig. 1.1.6. Schematic of UMT Micro-Indentation test set-up
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4.6.2
Micro-Indentation Test Script parameters
To perform micro-indentation, a test script with 3 Sequences is required: Initial Loading with 1 step, Microindentation with 5 steps, and Lift-up-and-Move with 1 step. The test script parameters for all the three sequences are described below:
TEST SEQUENCE-1: Engage > Touch Force: -0.1N; Pretouch: 0.1; Touch: 0.005; Tracking: 0.005mm/s Test > Tolerance (N): Positive 0.01; Negative 0.01 Disengage > Z-carriage Retracting Distance: 0 mm; Velocity: 0 mm/s. Data File> Uncheck 'Create data file'; No data recording Sequence Note > Initial loading STEP 1: //To apply initial load// General > Carriage > Linear(spindle) > Slider > TEST SEQUENCE-2: Touch Force: -0.1N; Pretouch: 0.2; Touch: 0.2; Tracking: 0.02mm/s Test > Tolerance (N): Positive 0.05; Negative 0.05 Disengage > Z-carriage Retracting Distance: 0 mm; Velocity: 0 mm/s. Data File> File name: give suitable file name such as C:\Trib\Test\....... Check 'Create data file'; Check Fz, C (Capacitance Sensor) and T (time) channels. Filter width: 10 samples Sequence Note > Microindentation STEP 1: //Loading up to 30 N load// General > Carriage > Linear(spindle) > Slider > Controlled: Carriage/Load; Step: Linear Force (Fz) by Time; Duration: 40 s. Force From: -0.2 N; To: -30 N Distance: 0; Velocity: 0 Position: Idle Engage > Controlled: Carriage/Load; Step: Constant Force (Fz); Duration: 10 s. Force: -0.2 N Distance: 0; Velocity: 0 Position: Idle
STEP 2: //Holding at maximum constant load of 30 N// General > Controlled: Carriage/Load; Step: Constant Force (Fz); Duration: 30 s. Carriage > Force: -30 N Linear(spindle) > Distance: 0; Velocity: 0 Slider > Position: Idle
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STEP 3: //Unloading to 10% of maximum load // General > Controlled: Carriage/Load; Step: Linear Force (Fz) by Time; Duration: 40 s. Carriage > Force From: -30 N; To: -3 N Linear(spindle) > Distance: 0; Velocity: 0 Slider > Position: Idle STEP 4: //Holding at 10% of maximum// General > Controlled: Carriage/Load; Step: Constant Force (Fz); Duration: 15 s. Carriage > Force: -3 N Linear(spindle) > Distance: 0; Velocity: 0 Slider > Position: Idle STEP 5: //Complete unloading // General > Controlled: Carriage/Load; Step: Linear Force (Fz) by Time; Duration: 5 s. Carriage > Force From: -3 N; To: 0.0 N Linear(spindle) > Distance: 0; Velocity: 0 Slider > Position: Idle TEST SEQUENCE-3: Engage > Test > Disengage > Data File> Sequence Note > Touch Force: -0.1N; Pretouch: 1.0; Touch: 1; Tracking: 0.5 mm/s Tolerance (N): Positive 10; Negative 10 Z-carriage Retracting Distance: 0 mm; Velocity: 0 mm/s. Uncheck 'Create data file'; No data recording Lift-up and Move Right by Slider
STEP 1: //To lift up carriage and move right by 0.2 mm using slider// General > Carriage > Linear (spindle) > Slider > Controlled: Carriage/Position; Step : Increment Carriage Displacement; Duration: 2 s. Offset: 1 mm; Velocity: 2 mm/s; Direction: Up Distance: 0; Velocity: 0 Velocity: manual-working 0.1 mm/s; Direction: Right; Position: increment; Offset: 0.2 mm.
IMPORTANT NOTE: The above script is an example of microindentation up to 30 N load assuming that a 200 N (20 kg) force sensor is installed in UMT. The unit of force is in Newton. If your UMT option file has a different unit of force (Fz), change the force values in the script accordingly. Make sure sensor protection in options is on. You can check it by clicking Options>Edit>Channels>Fz>check warn if absolute value exceeds... and check abort if absolute value exceeds. The force values for warn and abort actions are to be set at a little less than the full scale. Such sensor protection check is necessary to avoid damaging the sensor. Try the above script initially once. Open the test data (.tst) file and process the data using UMT Viewer. Please remember that Viewer option setting (Force and displacement channels and type of indenter etc) has to be changed accordingly in the indentation page in the Viewer. The indentation page can be accessed by clicking View>Options>Indentation in UMT Viewer. The engage parameters may slightly vary from one system to other due mainly to a variation of 15 YEARS OF LEADERSHIP IN MECHANICAL AND TRIBOLOGY TEST INSTRUMENTATION
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system stiffness. For multiple indentation tests, repeat the tests as many times as needed at the start of the test. Make sure that the capacitance probe lies within the reference plate during performing multiple indents. 4.6.3 Micro-Indentation Data Processing with Data Viewer
After performing a Micro-Indentation test with Fz and C channels recorded, open the Data Viewer but do not load the data file yet and click View => Options instead:
A new window will open. Click on Indentation tab and enter these settings here:
1) Make sure the following settings have been UNchecked: Automatic Cycle Type Detection Nanohead-compliant data Warn about data processing problems Use the latest tip calibration Loading Time Calculations 2) Enter Channels Names: Force: Fz Displacement: C 3) Data Fitting Maximum: 1000 4) Indenter Tip ID: 0 (Zero) 5) Type: the one that have been used for current test (say, Rockwell) 6) Cone Angle: that of the current tip (say, 120 deg for Rockwell) 7) Tip Radius: that of the current tip (say, 200000 nm for Rockwell) 8) Correction Factor : either 1 (default) or real if known 9) Constraint Factor: 0 (Zero) 10) Material: Indenter tip material (e.g. Diamond) 11) Poisson Ratio and Youngs Modulus: click Default Please note that all settings above are these of the tip but not of the sample being indented.
Click OK and then open the micro-indentation data file (make sure NOT to check Open all data in single step tab). Click Nanoindentation Graph button
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A new window will open. Enter Poisons ratio and other coefficients corresponding to the material being indented. Enter 0 (Zero) for Frame Stiffness. Click Calculate button every time after changing a parameter.
Elastic modulus and Hardness of the sample appear on the right.
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4.7 Mechanical (Combined Tension or Compression, and Torsion) Testing

4.7.1 Introduction
CETR Universal Materials Tester UMT is capable of performing standard tension and compression tests as per ASTM D638-02 and ASTM D3039-00. Such mechanical tests can also be performed with simultaneous tension/compression and torsion (twist) with synchronous motion of the upper carriage and the lower rotary drive. In one cycle, the test specimen can undergo tension and twist in one direction, and during the next cycle, it can be subjected to compression and twist in the opposite direction. Thus, UMT can be successfully used for performing repetitive tension, compression and twisting tests for fatigue, if performed for sufficient number of test cycles. UMT users have option of performing mechanical tests in either load-controlled or displacement-control mode, and can also program the direction and angle of twist. The normal force (Fz), displacement (Z-carriage position), angle of twist can be recorded as a function of time during the test. With force-controlled tests, the displacement changes with the test cycles, with displacement-controlled test, Fz changes as the test progresses.
4.7.2
Mechanical Test System Setup
Hardware Configuration: 4 Mounting Block Dual Friction/Load Sensor Upper Grip Lower Grip Lower Rotation Drive - Mod. S25UE or S21ME
Data Collection: The following should be checked under Data File: Fz Normal Force T Time Z1 Carriage Position Z2 Spindle Position
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4.7.3
Mechanical Test Script Parameters
Load-controlled Tensile Test
Mount a test specimen, load the relevant UMT option file, open a test script, set engage parameters, prepare, and run the following two test sequences:
SEQUENCE 1: To apply a small initial load Step 1: General : Controlled- Carriage/Load; Step-Constant Force; Check Pull Test; Duration- 5 s. Carriage : set the small initial load with no negative sign Spindle : Idle Slider : Idle SEQUENCE 2: To apply a linearly increasing load Step 1: General : Controlled- Carriage/Load; Step-Linear force (Fz) by Time; Check Pull Test; Duration- 10 s or as per required loading rate. Carriage : set initial load from step 1 in Sequence 1, and final load with no negative sign Spindle : Idle Slider : Idle Record Fz, Z1 (carriage position) and Time in a test file (.tst) at relevant location. Displacement-controlled Tensile Test
SEQUENCE 1: To move up the carriage for tensile testing Step 1: General : Controlled- Carriage/Position; Step-Increment Carriage Displacement; Duration- 10 s or as per required strain rate. Carriage : set offset = 20 mm or distance as required; Direction -up Spindle : Idle Slider : Idle Record Fz, Z1 (carriage position) and Time in a test file (.tst) at relevant location. Load-controlled Simultaneous Tensile (compression)-Torsion Test
SEQUENCE 1: To Initialize the carriage and spindle encoders Step 1: General : Controlled- Carriage/Load; Step-Constant Force (Fz) by Time; Check Pull Test; Duration- 2 s. Carriage : set the small initial load with no negative sign; Check reset position in the beginning of this step Spindle : Idle; Check reset position in the beginning of this step Slider : Idle
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SEQUENCE 2: To perform tension-twist-compression-twist back tests Step 1: Loading and Twist General : Controlled- Carriage/Load; Step-Linear force (Fz) by Time; Check Pull Test; Duration- 6 s; Carriage : set initial load and final load with no negative sign Spindle : Move-increment; Distance-0.1 rev; Velocity - 1 rpm; Direction- Counter clockwise Slider : Idle NOTE: User should set duration, distance, and velocity as required. Step 2: Loading and twisting in opposite direction General : Controlled- Carriage/Load; Step-Linear force (Fz) by Time; Check Pull Test; Duration- 6 s; Carriage : set initial load = final load in Step 1; final load = initial load in Step 1, with no negative sign Spindle : Move-increment; Distance-0.1rev; Velocity - 1 rpm; Direction- Clockwise Slider : Idle NOTE: User should set duration, distance, and velocity as per Step 1.
Record Fz, Z1 (carriage position), spindle position, and Time in a test file (.tst) at relevant location. For fatigue test under above tension (compression)-twist conditions, repeat the SEQUENCE 2 for relevant numbers of cycles.
Displacement-controlled Simultaneous Tensile (compression)-Torsion Test
Mount a test specimen, load the relevant UMT option file, open a test script, set engage parameters, prepare and run the following two test sequences:
SEQUENCE 1: To Initialize the carriage and spindle encoders Step 1: General : Controlled- Carriage/Position; Step-Increment Carriage Displacement; Duration- 1 s. Carriage : set offset = 0.0 mm ; Check reset position in the beginning of this step Spindle : Idle; Check reset position in the beginning of this step Slider : Idle SEQUENCE 2: To perform tension-twist-compression-twist back tests Step 1: Loading and Twist General : Controlled- Carriage/Position; Step-increment Carriage Displacement; Duration- 6 s; Carriage : set offset = 0.5 mm, Direction - up Spindle : Move-increment; Distance-0.1rev; Velocity - 1 rpm; Direction- Counter clockwise Slider : Idle NOTE: User should set duration, distance, and velocity as required. Step 2: Loading and twisting in opposite direction General : Controlled- Carriage/position; Step-increment Carriage Displacement; Duration- 6 s; Carriage : offset = 0.5 mm, Direction - down Spindle : Move-increment; Distance-0.1rev; Velocity - 1 rpm; Direction- Clockwise Slider : Idle NOTE: User should set duration, distance, and velocity as per Step 1.
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Record Fz, Z1 (carriage position), spindle position, and Time in a test file (.tst) at relevant location. For fatigue test under above tension (compression)-twist conditions, repeat the SEQUENCE 2 for relevant numbers of cycles. 4.7.4 Processing Mechanical Test Data Using UMT Viewer
Open the test data file with the UMT Viewer. Check (select) both the parameters (Fz and Z) and then click on the combo (arrow) of the "Elastomer Graph" button. Click on 'Tensile Stress' to open a calculation window. Enter relevant parameters related to the test specimen, such as shape and dimensions then click on 'Calculate" button to calculate the mechanical properties of the specimen and to make a stress vs. strain plot. For printing the plots and the calculated data, click on Print button. You can also obtain a preview by clicking on the 'print preview' button. To calculate the chord and secant moduli between two points, place two markers by clicking right mouse button on the stress vs. strain plot and press 'Calculate". UMT Viewer is capable of calculating yield strength, ultimate strength, Youngs modulus, chord modulus, secant modulus, percentage of elongation, toughness, and energy at yield point from load-displacement data of the specimen. 4.7.5 Typical Mechanical Test Results
Fig. 1 shows the force (Fz) and displacement (Z) plots vs. time for a specimen that was tested in load-controlled tensile test mode. Fig. 2 presents the stress-strain plot after processing the test data of Fig. 1. Fig. 3 presents force and displacement plot as function of time for a specimen that was tested in displacement-controlled test mode. Fig. 4 shows a stress-strain plot of a specimen obtained after processing the test data (Fig. 3) with UMT Viewer for mechanical properties. Fig. 5 shows the force and displacement plots of a specimen as a function of time for forcecontrolled tension-torsion test. The specimen was tested in the tensile force range of 1 N to 5 N, and twisted 0.1 revolution at 1 rpm speed for several cycles. The displacement at maximum force was initially low (230 micron) which gradually increased (298 micron) at the last cycle of the test. Such increase in plastic strain under constant load can be attributed to the degradation of the mechanical properties of the specimen due to fatigue. Fig. 6 shows the force and displacement plots as a function of time for displacement- controlled tension-torsion test on a specimen. The specimen was stretched over a length of 500 micron and twisted for 0.1 revolution at 1 rpm speed for several cycles. The force at maximum displacement was initially higher (6.1 N) which gradually decreased (4.7 N) as test progressed, indicating fatigue.
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Fig. 1. Force and displacement (Z) vs. time plots for load-controlled tensile test
Fig. 2. Stress-strain plot after processing Fz-Z data in Fig. 1 using UMT Viewer.
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Fig. 3. Force and displacement vs. time plots for displacement-controlled tensile test
Fig.4. Stress-strain plot after processing Fz-Z data in Fig. 3 using UMT Viewer.
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Fig.5. Force and displacement vs. time plots for force-controlled tension-torsion test
Fig.6. Force and displacement vs. time plots for displacement-controlled tension-torsion test
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4.7.6 Summary Universal Materials Tester UMT is capable of performing numerous mechanical tests to obtain yield strength, ultimate strength, Youngs modulus, chord modulus, secant modulus, percentage of elongation, toughness, and energy at yield point from load-displacement data (stress-strain) of test specimen. UMT is also capable of synchronized and repetitive tension/compression and torsion testing for fatigue conditions.
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Application Notes for Various ASTM Tests

5.1 Ball/Pin-on-Disk Wear Test Using the Micro-Tribometer mod. UMT-2 with Rotational Motion Drive - ASTM G99-95
Test method for determining the wear of materials during sliding using the UMT in a ball or pin-on-disk configuration. Summary of Test Method: This test method involves a ball shaped upper specimen that slides against a rotating disk as a lower specimen under a prescribed set of conditions. The load is applied vertically downward with a motor driven carriage that uses the force/load sensor for feedback to maintain a constant load.The UMT allows for monitoring during the test the actual dynamic normal load, friction force and friction coefficient, and depth of wear. Optionally, it can measure additional parameters of contact acoustic emission, electrical contact resistance, and temperature. ASTM G99-95 does not specify test parameters such as rpm, load, or test duration. The configuration below is an example of one of many possible combinations of friction/load sensor, rotational drive, specimen holder, and specimens. UMT Hardware Configuration: 4 Mounting Block PN M30C116 Model DFH-2 Dual Friction/Load Sensor - range 0.2 N to 20 N Suspension with Linear Guide-AM30C110D-1 3/8 Ball Holder AM30B310B - for sensors mod. DFH 440-C Stainless Steel Ball, Dia. 3/8- PN BM110006 Stainless Steel Disk Medium Torque Rotation Drive - Mod. SHHM Optional Additional Sensors - mod AE-5 Acoustic Emissions Sensor - mod ECR-xx Electrical Contact Resistance - mod. TMR-150 Temperature Measurement & Recording
UMT Software Test Setup: UMT Options File: Load the options file that contains settings for the Medium Torque Rotational Motion Drive and the 20 N force/load sensor. Use the Semi-Automatic Mode to pre-position the x-axis slider so that 15 YEARS OF LEADERSHIP IN MECHANICAL AND TRIBOLOGY TEST INSTRUMENTATION
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the ball is 16 mm from the center of rotation of the lower specimen. This will create a circular wear track with a diameter of 32 mm. Test Sequence: Sheet 1 is for settling time for the carriage to establish the initial normal load. Carriage - applies a 10 N Constant Force for a Duration of 10 sec. Spindle Velocity is 0 revs/min. Slider is idle. Sheet 2 is a 16 min. 40 sec. period Carriage - applies a 10 N Constant Force for a Duration of 10000 seconds. Spindle Velocity is 60 revs/min, Move-Continuous, and Direction- Clockwise Slider is idle. Data Collection: The following should be checked under DataFile: Fx Friction Force Fz Normal Force T Time Z1 Carriage Position (Used to determine Wear Depth) Te - input Temperature (optional) AE Acoustic Emission (optional) EC Electrical Contact Resistance Report: Use the Viewer program to plot test results. Select the parameters to be displayed by checking the appropriate boxes under Parameters on the Viewer screen.
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5.2 Ball-on-Flat Sliding Wear Test using the Micro-Tribometer mod. UMT-2 with Linear Reciprocating Motion Drive - ASTM G 133-95
This is a standard test method for determining the sliding wear of ceramics, metals, and other wearresistant materials using the linear reciprocating ball-on-flat geometry. Summary of Test Method: This test method utilizes a flat lower specimen and a ball-shaped upper specimen that slides against the flat specimen. These specimens move relative to one another in a linear, back and forth sliding motion, under a prescribed set of conditions. In this test method, the load is applied vertically downward through the ball specimen against the horizontally mounted flat specimen. The normal load, stroke length, frequency of oscillation, test temperature, lubricant, and test duration are selected from one of two procedures. Test Parameters Applied Load Stroke Length 25.0 N 10.0 mm 200.0 N 10.0 mm
Procedure A B
Lube No Yes
Temperature Ambient 150C
Osc. Frequency 5.0 Hz 10.0 Hz
Duration 16 min. 40 sec. 30 min. 20 sec.
UMT Hardware Configuration for Procedure A: 4 Mounting Block PN M30C116 2 Mounting Block PN M30C166 Model DFH-5 Dual Friction/Load Sensor - range 0.5 N to 50 N Suspension with Linear Guide-AM30C110D-1 3/8 Ball Holder AM30B310B - for sensors mod. DFH 3/8 Diameter Ball Specimen Lower linear Reciprocating Motion Drive Manually adjust for 10 mm travel. - mod. RMH Optional Additional Sensors - mod. ECR-xx Electrical Contact Resistance - mod. TMR-150 Temperature Measurement & Recording
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UMT Software Test Setup for Procedure A: UMT Options File: Load the options file that contains settings for the Linear Reciprocating Motion drive and the 50 N force/load sensor. Test Sequence: Sheet 1 is for settling time for the carriage to establish the initial normal load. Carriage - applies a 25 N Constant Force for a Duration of 10 sec. Spindle Velocity is 0 revs/min. Slider is idle. Sheet 2 is a 16 min. 40 sec. period Carriage - applies a 25 N Constant Force for a Duration of 1000 seconds. Spindle Velocity is 300 revs/min, Move-Continuous, and Direction- Clockwise Slider is idle. Data Collection: The following should be checked under DataFile: Fx Friction Force Fz Normal Force T Time Z1 Carriage Position (Used to determine Wear Depth) Te input Temperature (optional) AE Acoustic Emission (optional) EC Electrical Contact Resistance (optional) UMT Hardware Configuration for Procedure B: 4 Mounting Block PN M30C116 Model DFH-50 Dual Friction/Load Sensor - range 5.0 N to 500 N Suspension with Linear Guide-AM30C110D-1 3/8 Ball Holder AM30B310B - for sensors mod. DFH 3/8 Diameter Ball Specimen Elevated Temperature Chamber for Reciprocating Drive Lower linear Reciprocating Motion Drive Manually adjust for 1 travel. - mod. RHH Optional Additional Sensors - mod. ECR-xx Electrical Contact Resistance - mod. AE-5 Contact Acoustic Emission Detector - mod. TMR-150 Temperature Measurement & Recording 15 YEARS OF LEADERSHIP IN MECHANICAL AND TRIBOLOGY TEST INSTRUMENTATION
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UMT Software Test Setup for Procedure B: UMT Options File: Load the options file that contains settings for the Linear Reciprocating Motion drive and the 500N force/load sensor. Test Sequence: Sheet 1 is for settling time for the carriage to establish the initial normal load. Carriage - applies a 200 N Constant Force for a Duration of 10 sec. Spindle Velocity is 0 revs/min. Slider is idle. Sheet 2 is a 30 min. 20 sec. period Carriage - applies a 200 N Constant Force for a Duration of 1820 seconds. Spindle Velocity is 600 revs/min, Move-Continuous, and Direction- Clockwise Slider is idle. Data Collection: The following should be checked under DataFile: Fx Friction Force Fz Normal Force T Time Z1 Carriage Position (Used to determine Wear Depth) Te input Temperature (optional) ECR Electrical Contact Resistance (optional) Report: Use the Viewer program to plot test results. Select the parameters to be displayed by checking the appropriate box under Parameters on the Viewer screen. For viewing COF plots of reciprocating tests check the Fz box, click on the Symmetry button, click on the Peak Detect button, and then check the COF box.
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5.3 Standard Test Method for Ranking Resistance of Plastics to Sliding Wear in Block-on-Ring Wear Test (Cumulative Wear Method) Using Micro-Tribometer mod. UMT-2 - ASTM G176-03
Summary of Test Method: This test method covers the procedure for determining sliding wear of plastic materials using the block-on-ring geometry. A stationary block specimen is pressed with a constant force against a rotating ring specimen at 90 to the rings axis of rotation. Friction between the sliding surfaces of the block and ring results in loss of material from both pieces. Many materials can be fabricated into blocks and rings, however the standards emphasis is on plastics. The test may be run with different gaseous atmospheres and elevated temperatures to simulate the service conditions. The standard lists typical parameters: Ring dimensions 35 mm dia. x 8.7 mm width Block dimensions 6.35 mm x 10.2 mm x 15.8 mm Normal load 44.3 N Velocity 200 rpm Duration 20 hrs Wear test results are reported as the volume loss in cubic millimeters for both the block and ring. . The UMT-2 can additionally measure in-situ (during the test) dynamic wear depth, friction force and coefficient. Additionally, acoustic emission and temperature can be measured. The following is a typical test setup.
UMT Hardware Configuration: 4 Mounting Block PN M30C116 Model DFH-10 Dual Friction/Load Sensor - range 1 to 100 N Upper Specimen Holder for Blocks - for sensors mod. DFH Suspension with Linear Guide Upper Specimen Test Block Lower Block-on-Ring Drive . BHHM Lower Specimen Test Ring Optional Additional Sensors - mod. AE-5 Contact Acoustic Emission Detector - mod. TMR-150 Temperature Measurement & Recording
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UMT Software Test Setup: UMT Options File: Load the options file which contains settings for the block-on-ring drive and the 100 N force/load sensor. Test Sequence: Sheet 1 is for settling time for the carriage to establish the initial normal load. Carriage - applies a 44.3 N Constant Force for a Duration of 10 sec. Spindle Velocity is 0 revs/min. Slider is idle. Sheet 2 is the wear-life test period Carriage - applies a 44.3 N Constant Force for a Duration of 20 hrs. Spindle Velocity is 200 revs/min, Move-Continuous, and Direction- Counterclockwise Slider is idle. Data Collection: The following should be checked under DataFile: Fx Friction Force Fz Normal Force T Time Z1 Carriage Position (Used to determine Wear Depth) AE input Acoustic Emission (optional) Te input Temperature (optional) Report: Use the Viewer program to plot test results. Select the parameters to be displayed by checking the appropriate box under Parameters on the Viewer screen.
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5.4 Scratch Hardness Test Using a Diamond Stylus on the Micro-Tribometer mod. UMT-2 - ASTM G171-03
Summary of Test Method: This test method is used to determine the scratch hardness number of the surfaces of solid materials. The test involves producing a scratch by moving a diamond stylus along a specified path under a constant normal force and with a constant speed. The average width of the scratch is measured on a separate instrument. The scratch hardness number is computed as follows; the applied force is divided by the scratch width and the result is multiplied by a geometrical constant The UMT maintains a constant normal force with its servo-controlled system. An x-axis slider moves the diamond stylus across the test specimen to produce the scratch. The friction/load sensor also measures the tangential scratching force for computing the stylus drag coefficient. Lubricant None Test Parameters Temperature Applied Load Ambient 200 g * Stroke Length Speed 5 mm minimum 0.2 to 5.0 mm/s
The applied load may vary depending on the material being tested. It must be sufficient to produce a measurable and repeatable scratch.
The diamond stylus is conical with an apex angle of 120 and a hemispherical tip radius of 200 m.The UMT allows for monitoring during the test the actual dynamic normal force, scratching force and drag coefficient, and depth of scratch. Additionally, the acoustic emissions produced during the test may be recorded. UMT Hardware Configuration: 4 Mounting Block PN M30C116 Model DFM-0.5 Dual Friction/Load Sensor - range 5 to 500 g Suspension PN AM30B825-1 Pin Holder - PN AM30B534 - for sensors mod. DFM Diamond Tip Indenter Class A, B Test Specimen Stationary Specimen Table Optional Additional Sensor - mod. AE-5 Contact Acoustic Emission Detector
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UMT Software Test Setup: UMT Options File: Load the options file that contains settings for 500 g force/load sensor. Test Sequence: Sheet 1 is for settling time for the carriage to establish the initial normal load. Carriage - applies a 200 g Constant Force for a Duration of 10 sec. Spindle Velocity is 0 revs/min. Slider is idle. Sheet 2 is for the actual scratch test. Carriage - applies a 200 g Constant Force for a Duration of 30 sec. Spindle Velocity is 0 revs/min. Slider Velocity is 0.33 mm/sec., Increment Offset is 10 mm, and Direction is left. Data Collection: The following should be checked under DataFile: Fx Friction Force Fz Normal Force T Time Z1 Carriage Position (Used to determine Wear Depth) Z3 Slider Position Report: Use the Viewer program to plot test results. Select the parameters to be displayed by checking the appropriate box under Parameters on the Viewer screen. For viewing stylus drag coefficient plots click on the COF box.
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5.5 Vickers Hardness Test Using a Diamond Indenter on the Universal Materials Tester mod. UMT-3 or Apex - ASTM E92-82
Summary of Test Method: Vickers hardness testan indentation hardness test using calibrated machines to force a square-based pyramidal diamond indenter having included face angles of 136, under a predetermined force, into the surface of the material under test and to measure the diagonals of the resulting impression after removal of the force. Vickers hardness number, HVa number related to the applied force Fz and the surface area of the resultant permanent impression: HV = 2Fz sin (/2)/d 2 = 1.8544Fz/d 2 , where Fz = force, kg, d = mean diagonal of impression, mm, and = 136 (face angle of diamond) Lubricant None Test Parameters Temperature Applied Load Ambient 1 to 120 kg Duration 10 15 sec.
UMT Hardware Configuration: 4 Mounting Block PN M30C116 Model DFH-120 Dual Friction/Load Sensor range 20 to 120 kg (for loads 20 120 kg) Model DFH-20 Dual Friction/Load Sensor - range .2 to 20kg (for loads 1 to 20 kg) Suspension for sensor model DFH Pin Holder - PN AM30B264 Vickers Diamond Indenter Test Specimen Stationary Specimen Table Optional Visual Modules; Microscope, 3D Profiler The UMT/Apex allows actual dynamic normal force monitoring during the test. Thus, any discrepancy in measured results can be verified with recorded force data. UMT Software Test Setup: Test Sequence: (example) The Test Sequence should consist of 1 sheet (repeated 5 10 times randomly distributed) Carriage - applies a 1kg Constant Force for a Duration of 15 sec. Spindle Velocity is 0 revs/min. Slider is idle. 15 YEARS OF LEADERSHIP IN MECHANICAL AND TRIBOLOGY TEST INSTRUMENTATION
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Data Collection: The following should be checked under DataFile: Fx Friction Force Fz Normal Force T Time Z1 Carriage Position (Used to determine Depth) Report: Diagonals measured on the 3D Profiler
Indent 1
Indent 2
Indent 3
Indent 4
Indent 5
Diagonal X Diagonal Y Avg. Diagonal X Diagonal Y Avg. Diagonal X Diagonal Y Avg. Diagonal X Diagonal Y Avg. Diagonal X Diagonal Y Avg.
0.332 0.332 0.332 0.332 0.332 0.332 0.329 0.342 0.3355 0.317 0.33 0.3235 0.32 0.33 0.325 0.3296
HV (Avg.)
16.82
HV (Avg.)
16.82
HV (Avg.)
16.42
HV (Avg.)
17.66
HV (Avg.) 17.55 HV 17.13
Overall Avg.
The UMT/Apex accuracy is 2%, which is better than the standard specified 4% of the Vickers hardness number of the standardized reference hardness test blocks. 15 YEARS OF LEADERSHIP IN MECHANICAL AND TRIBOLOGY TEST INSTRUMENTATION
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5.6 Standard Test for Wear Rate and Coefficient of Friction of Materials in SelfLubricating Rubbing Contact with a Thrust Washer Using the Micro-Tribometer mod. UMT-2 - ASTM D3702-94
Summary of Test Method: This test method involves a rotating test specimen pressed against a stationary steel washer under a prescribed set of conditions. The test specimen is disk shaped with a raised outer rim, which is the wear surface. The inside diameter of the rim is 25.5 mm, the outer diameter is 28.55 mm. Each test has a break-in period of 40 hours, followed by a selected test duration at the same load and speed (see table below). Wear rate and coefficient of friction are calculated based on periodic thickness measurements of the test specimen and in-situ torque measurements. The UMT applies a programmable load downward by a servo driven carriage. The test can be performed with either Configuration A: the upper test specimen is rotated against a stationary washer as described in the standard, or Configuration B: the upper test specimen is stationary and the washer is rotated. The actual dynamic normal load, friction torque and coefficient, and depth of wear are monitored during the
test. Optionally, additional parameters of contact acoustic emission and temperature are measured.
Rotational Rubbing Velocity, Speed, rpm m/min 36 3.05 180 15.2 900 76.2 UMT Hardware Configuration A:
Test Conditions Load, kg ,to obtain PV, kg/cm x m/min PV1 26.8 PV2 53.6 PV3 107.1 PV4 214.3 11.3 22.7 45.4 90.7 2.3 4.5 9.1 18.1 0.5 0.9 1.8 3.6
Upper Rotational Motion Drive mod. USMHH Model TH 6-axis Torque/Force Sensor - Torque Range: 5 to 1000 N*mm - Load Range: 0.05 to 5 kg Suspension with Linear Guide-AM30C110F-1 Test Specimen Holder Test Specimen Washer Washer Holder Stationary Table Optional Additional Sensors - mod AE-5 Acoustic Emissions Sensor - mod. TMR-150 Temperature Measurement & Recording
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UMT Software Test Setup for Configuration A: UMT Options File: Load the options file that contains settings for the Upper Rotational Motion Drive and the 5 kg torque/force sensor.Use the Semi-Automatic Mode to pre-position the x-axis slider so that the test specimen is concentric with the washer. Test Sequence: Sheet 1 is for settling time for the carriage to establish the initial normal load. Carriage - applies a 1.1 kg Constant Force for a Duration of 10 sec. Spindle 1 Velocity is 0 revs/min. Spindle 2 Velocity is 0 revs/min. Slider is idle. Sheet 2 is a 40 hour break-in period Carriage - applies a 1.1 kg Constant Force for a Duration of 40 hours. Spindle 1 Velocity is 0 revs/min. Spindle 2 Velocity is 180 revs/min, Move-Continuous, and Direction- Clockwise Slider is idle. Sheet 3 is a 100 hour test period Carriage - applies a 1.1 kg Constant Force for a Duration of 100 hours. Spindle 1 Velocity is 0 revs/min. Spindle 2 Velocity is 180 revs/min, Move-Continuous, and Direction- Clockwise Slider is idle. Data Collection: The following should be checked under DataFile: Tz Torque T Time Z1 Carriage Position (Used to determine Wear Depth) Te - input Temperature (optional) AE Acoustic Emission (optional) EC Electrical Contact Resistance
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UMT Hardware Configuration B: 4 Mounting Block PN M30C116 Model TH 6-axis Torque/Force Sensor - Torque Range: 5 to 1000 N*mm - Load Range: 0.05 to 5 kg Suspension with Linear Guide-AM30C110F-1 Test Specimen Holder Test Specimen Washer Washer Holder Medium Torque Rotation Drive - Mod. SHHM Optional Additional Sensors - mod AE-5 Acoustic Emissions Sensor - mod. TMR-150 Temperature Measurement & Recording UMT Software Test Setup for Configuration B: UMT Options File: Load the options file that contains settings for the Medium Torque Rotational Motion Drive and the 5 kg torque/force sensor. Use the Semi-Automatic Mode to pre-position the x-axis slider so that the test specimen is concentric with the axis of the rotational drive. Test Sequence: The Test Sequence should consist of 3 sheets. Sheet 1 is for settling time for the carriage to establish the initial normal load. Carriage - applies a 1.1 kg Constant Force for a Duration of 10 sec. Spindle Velocity is 0 revs/min. Slider is idle. Sheet 2 is a 40 hour break-in period Carriage - applies a 1.1 kg Constant Force for a Duration of 40 hours. Spindle Velocity is 180 revs/min, Move-Continuous, and Direction- Clockwise Slider is idle. Sheet 3 is a 100 hour test period Carriage - applies a 1.1 kg Constant Force for a Duration of 100 hours. Spindle Velocity is 180 revs/min, Move-Continuous, and Direction- Clockwise Slider is idle.
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Data Collection: The following should be checked under DataFile: Tz Torque T Time Z1 Carriage Position (Used to determine Wear Depth) Te - input Temperature (optional) AE Acoustic Emission (optional) ECR Electrical Contact Resistance Report: Use the Viewer program to plot test results. Select the parameters to be displayed by checking the appropriate boxes under Parameters on the Viewer screen.
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5.7 Cross-Cylinder Test using Micro-Tribometer mod. UMT-2 - ASTM G83 96

Standard Test Method for Ranking Metallic Pairs in their Resistance to Sliding Wear Summary of Test Method: In the crossed-cylinder wear test, two cylindrical specimens are perpendicular to each other, one rotating and the other stationary. The lower specimen is mounted on a block-on-ring drive and can rotate at speeds from 0.1 rpm to 5000 rpm (the standard speeds are up to 400 rpm). The upper non-rotating specimen is pressed against the rotating specimen at a programmed servo-controlled load. There are 3 procedures: procedure A for materials that have high wear-resistance, procedure B as a shorter test, and procedure C for low wear-resistance materials. The following table lists parameters for each of the procedures. Test Parameters Load, N Speed, rpm 71.2 400 71.2 400 71.2 100
Procedure A B C
Duration, min. 200 100 100
The cylinder specimens can have diameters from 3 mm to 25 mm (standard-recommended is 12.7 mm) and lengths from 20 mm to 120 mm (standard-recommended is 102 mm). The standard recommends to measure weight loss for wear characterization. The UMT-2 can additionally measure in-situ (during the test) dynamic wear depth, friction force and coefficient.
UMT Hardware Configuration: 4 Mounting Block PN M30C116 Model DFH-10 Dual Friction/Load Sensor - range 0.01 to 10 kg Suspension for Dual Sensor with Linear Guides - PN AM30C110D-2 Upper Specimen Cylinder Holder for sensors mod. DFH - PN M30B398 Mounting Chuck for Lower Cylinder Block-on-Ring Drive - mod. BHHM Optional Additional Sensors - mod. AE-5 Contact Acoustic Emission Detector - mod. TMR-150 Temperature Measurement & Recording - mod. RTD Temperature Sensor
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UMT Software Test Setup: UMT Options File: Load the options file which contains settings for the block-on-ring drive and the 10 kg force/load sensor. Test Sequence: The Test Sequence should consist of 2 sheets. Sheet 1 is for settling time for the carriage to establish the initial normal load. Carriage - applies a 71.2 N Constant Force for a Duration of 10 sec. Spindle Velocity is 0 revs/min. Slider is idle. Sheet 2 is the wear-resistance test period Carriage - applies a 71.2 N Constant Force for a Duration of 200 minutes for Procedure A or 100 minutes for procedure B or C.. Spindle Velocity is 400 revs/min for Procedure A or B or 100 revs/min for Procedure C, Move- Continuous,, and Direction-Counter-clockwise. Slider is idle. Data Collection: The following should be checked under DataFile: Fx Friction Force Fz Normal Force T Time Z1 Carriage Position (Used to determine Wear Depth) AE Acoustic Emission (optional) Te Temperature (optional) Report: Use the Viewer program to plot test results. Select the parameters to be displayed by checking the appropriate box under Parameters on the Viewer screen.
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5.8 Pin Abrasion Testing Using the Micro-Tribometer UMT-2 - ASTM G132-96
Test method for determining the wear resistance of a pin of test material during sliding on an abrasive cloth, paper, or plastic film using the UMT in a pin-on-disk configuration, pin-ondrum configuration, and pin-on-flat (x-y) configuration. Summary of Test Method: In this test method the pin upper specimen is perpendicular to and sliding against the abrasive surface of a lower specimen which is mounted on either a flat circular disk, or a cylindrical of a drum, or a flat lateral positioning table. The wear track of the pin is a continuous, non-overlapping path such as a spiral, a helix, or a square wave. The UMT applies the load vertically downward with a motor driven carriage that uses a force/load sensor for feedback to maintain a constant load. The UMT allows for monitoring during the test the actual dynamic normal load, friction force and friction coefficient, and depth of wear. Optionally, it can measure additional parameters of contact acoustic emission and temperature. ASTM G132-96 does not specify test parameters such as rpm, load, or test duration, but lists typical parameters.
Pin Diameter 6.3 mm Load 67 N Translational Speed 0.04 m/sec. Pin Rotation None or 17 to 20 rpm Track Length 4 to 16m
Typical Test Results The Viewer software program is used to plot test results. The recorded parameters are displayed by checking the appropriate boxes such WR for wear and COF for coefficient of friction under Parameters on the Viewer screen.
Described on the following pages are six possible UMT configurations for performing this test: Non-rotating Pin on Rotating Disk Rotating Pin on Rotating Disk Non-rotating Pin on Rotating Drum Rotating Pin on Rotating Disk Non-rotating Pin on Flat Rotating Pin on Flat
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The configurations used in these examples are just a few of the many possible combinations of friction/load sensor, rotational drive, specimen holder, and specimens. Non-Rotating Pin-on-Disk Test Method: This test method uses a lower rotational drive with a 6 diameter specimen table on which an abrasive disk is fastened. While the lower drive rotates, the pin is slid across the abrasive disk with the x-axis stage. The wear track of the pin is a continuous, non-overlapping spiral path. The UMT automatically varies the rpm of the lower specimen and the velocity of the x-axis stage to maintain a constant translational speed between the pin and the disk. UMT Hardware Configuration for Non-Rotating Pin-on-Disk: 4 Mounting Block PN M30C116 Model DFH-10 Dual Friction/Load Sensor - range 1 N to 100 N Suspension with Linear Guide-AM30C110D-2 1/4 Pin Holder AM30B264B - for sensors mod. DFH 416 Stainless Steel Pin, Dia. 1/4, Length 0.5 - PN BM110006 Lapping Disk, Dia. 6, 3.0 micron Alumina particles Medium Torque Rotation Drive - Mod. SHHME Adapter Table, Dia. 6 - PN M30D089B Optional Additional Sensors - mod AE-5 Acoustic Emissions Sensor - mod. TMR-150 Temperature Measurement & Recording - mod. RTD Temperature Sensor
UMT Software Test Setup for Non-Rotating Pin-on-Disk: UMT Options File: Load the options file that contains settings for the Medium Torque Rotational Motion Drive and the 100 N force/load sensor. Use the Semi-Automatic Mode to pre-position the x-axis stage so that the pin is 5 mm from the center of rotation of the lower specimen. This will be the start of a non-overlapping spiral wear track with a length of 3 meters. The track radius expands by 6.35mm per revolution. The translational velocity is constant at 40 mm/sec. Test Sequence:
The Test Sequence should consist of 2 sheets. Sheet 1 is for settling time for the carriage to establish the initial normal load. Carriage - applies a -67 N Constant Force for a Duration of 10 sec. Spindle Velocity is 0 revs/min. Stage is idle.
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Sheet 2 is a 100 sec. period Carriage - applies a -67 N Constant Force for a Duration of 75 seconds. Spindle Velocity is 2400 mm /min, Move-Continuous, and Direction- Clockwise Stage Working Velocity is 6.35 mm/rev. spindle 1, Initial Positioning Velocity is 2 mm/sec., and Position is Absolute from 5 mm to 75 mm. Check Move Immediately. Data Collection: The following should be checked under DataFile: Fx Friction Force Fz Normal Force T Time Z1 Carriage Position (Used to determine Wear Depth) Te Temperature (optional) AE Acoustic Emission (optional)
Rotating Pin-on-Disk Test Method: This test method uses a lower rotational drive with a 6 diameter specimen table on which an abrasive disk is fastened. The pin is attached to the upper rotational drive. While the upper and lower drives rotate, the pin is slid across the abrasive disk with the x-axis stage. The wear track of the pin is a continuous, non-overlapping spiral path. The UMT automatically varies the rpm of the lower specimen and the velocity of the x-axis stage to maintain a constant translational speed between the pin and the disk. The upper rotational drive spins at a constant rpm. Because the pin is rotating, its wear is typically greater than that in the previous non-rotating pin test. UMT Hardware Configuration for Rotating Pin-on-Disk: Model USMHH Upper Rotational Drive Model DFH-10 Dual Friction/Load Sensor (internal to Upper Rotational Drive) - range 1 N to 100 N Suspension with Linear Guide-AM30C110D-2 1/4 Pin Holder AM30B264B - for sensors mod. DFH 416 Stainless Steel Pin, Dia. 1/4, Length 0.5 - PN BM110006 Lapping Disk, Dia. 6, 3.0 micron Alumina particles Medium Torque Rotation Drive - Mod. SHHME Adapter Table, Dia. 6 - PN M30D089B Optional Additional Sensors - mod AE-5 Acoustic Emissions Sensor - mod. TMR-150 Temperature Measurement & Recording - mod. RTD Temperature Sensor
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UMT Software Test Setup for Rotating Pin-on-Disk: UMT Options File: Load the options file that contains settings for the Medium Torque Rotational Motion Drive for spindle 1, and the Upper Rotational Drive with internal 100 N force/load sensor for spindle 2. Use the Semi-Automatic Mode to pre-position the x-axis stage so that the pin is 5 mm from the center of rotation of the lower specimen. This will be the start of a non-overlapping spiral wear track with a length of 3 m. The track radius expands by 6.35mm per revolution. The translational velocity is constant at 40 mm/s. Test Sequence: The Test Sequence should consist of 2 sheets. Sheet 1 is for settling time for the carriage to establish the initial normal load. Carriage - applies a -67 N Constant Force for a Duration of 10 sec. Spindle1 Velocity is 0 revs/min. Spindle2 Velocity is 0 revs/min. Stage is idle. Sheet 2 is a 100 sec. period Carriage - applies a -67 N Constant Force for a Duration of 75 seconds. Spindle1 Velocity is 2400 mm /min, Move-Continuous, and Direction- Clockwise Spindle2 Velocity is 20 rev /min, Move-Continuous, and Direction- Clockwise Stage Working Velocity is 6.35 mm/rev. spindle 1, Initial Positioning Velocity is 2 mm/sec., and Position is Absolute from 5 mm to 75 mm. Check Move Immediately. Data Collection: The following should be checked under DataFile: Fx Friction Force Fz Normal Force T Time Z1 Carriage Position (Used to determine Wear Depth) Te Temperature (optional) AE Acoustic Emission (optional)
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Non-Rotating Pin-on-Drum Test Method: This test method involves a pin upper specimen that slides against an abrasive surface of a drum mounted on a lower block-on-ring drive. While the lower drive rotates, the pin is slid across the abrasive surface with the x-axis stage. The rpm of the lower drive and velocity of the upper specimen are constant. The wear track of the pin is a continuous, non-overlapping helix. UMT Hardware Configuration for Non-Rotating Pin-on-Drum: 4 Mounting Block PN M30C116 Model DFH-10 Dual Friction/Load Sensor - range 1 N to 100 N Suspension with Linear Guide-AM30C110D-2 1/4 Pin Holder AM30B264B - for sensors mod. DFH 416 Stainless Steel Pin, Dia. 1/4, Length 0.5 - PN BM110006 Drum, Dia. 110mm, Length 80mm Block-on-Ring Drive - Mod. BHHM Optional Additional Sensors - mod AE-5 Acoustic Emissions Sensor - mod. TMR-150 Temperature Measurement & Recording - mod. RTD Temperature Sensor
UMT Software Test Setup for Non-Rotating Pin-on-Drum: UMT Options File: Load the options file that contains settings for the Block-on-Ring Drive and the 100 N force/load sensor. Use the Semi-Automatic Mode to pre-position the x-axis stage so that the pin is 5 mm from the right hand edge of the drum. This will be the start of a non-overlapping wear track with a length of 4 m. The x-stage moves to the left by 6.5mm per revolution of the drum. The translational velocity is constant at 40 mm/s. Test Sequence: The Test Sequence should consist of 2 sheets. Sheet 1 is for settling time for the carriage to establish the initial normal load. Carriage - applies a -67 N Constant Force for a Duration of 10 sec. Spindle Velocity is 0 revs/min. Stage is idle. Sheet 2 is a 100 sec. period Carriage - applies a -67 N Constant Force for a Duration of 100 seconds. Spindle Velocity is 6.95 rev. /min, Move-Continuous, and Direction- Clockwise Stage Working Velocity is .75 mm/sec., Initial Positioning Velocity is 2 mm/sec., and Position is Increment Offset 75 mm., Check Move Immediately, Direction Left. 15 YEARS OF LEADERSHIP IN MECHANICAL AND TRIBOLOGY TEST INSTRUMENTATION
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Data Collection: The following should be checked under DataFile: Fx Friction Force Fz Normal Force T Time Z1 Carriage Position (Used to determine Wear Depth) Te Temperature (optional) AE Acoustic Emission (optional) Rotating Pin-on-Drum Test Method: This test method involves a rotating pin upper specimen that slides against an abrasive surface of a drum mounted on a lower block-on-ring drive. The pin is attached to the upper rotational drive. While the upper and lower drives rotate, the pin is slid across the abrasive drum with the x-axis stage. The rpm of the upper and lower drives and the velocity of the x-axis stage are constant. The wear track of the pin is a continuous, non-overlapping helix. Because the pin is rotating, its wear is typically greater than that in the previous non-rotating pin test. UMT Hardware Configuration for Rotating Pin-on-Drum: Model USMHH Upper Rotational Drive Model DFH-10 Dual Friction/Load Sensor (internal to Upper Rotational Drive) - range 1 N to 100 N Suspension with Linear Guide-AM30C110D-2 1/4 Pin Holder AM30B264B - for sensors mod. DFH 416 Stainless Steel Pin, Dia. 1/4, Length 0.5 - PN BM110006 Drum, Dia. 110mm, Length 80mm Block-on-Ring Drive - Mod. BHHM Optional Additional Sensors - mod AE-5 Acoustic Emissions Sensor - mod. TMR-150 Temperature Measurement & Recording - mod. RTD Temperature Sensor
UMT Software Test Setup for Rotating Pin-on-Drum: UMT Options File: Load the options file that contains settings for the Block-on-Ring Drive for spindle 1, and the Upper Rotational Drive with internal 100 N force/load sensor for spindle 2. Use the Semi-Automatic Mode to pre-position the x-axis stage so that the pin is 5 mm from the right hand edge of the drum. This will be the start of a non-overlapping wear track with a length 15 YEARS OF LEADERSHIP IN MECHANICAL AND TRIBOLOGY TEST INSTRUMENTATION
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of 4 m. The x-stage moves to the left by 6.5mm per revolution of the drum. The translational velocity is constant at 40 mm/s. Test Sequence: The Test Sequence should consist of 2 sheets. Sheet 1 is for settling time for the carriage to establish the initial normal load. Carriage - applies a -67 N Constant Force for a Duration of 10 sec. Spindle1 Velocity is 0 revs/min. Spindle2 Velocity is 0 revs/min. Stage is idle. Sheet 2 is a 100 sec. period Carriage - applies a -67 N Constant Force for a Duration of 100 seconds. Spindle1 Velocity is 6.95 rev. /min, Move-Continuous, and Direction- Clockwise Spindle2 Velocity is 20 rev. /min, Move-Continuous, and Direction- Clockwise Stage Working Velocity is .75 mm/sec., Initial Positioning Velocity is 2 mm/sec., and Position is Increment Offset 75 mm., Check Move Immediately, Direction Left. Data Collection: The following should be checked under DataFile: Fx Friction Force Fz Normal Force T Time Z1 Carriage Position (Used to determine Wear Depth) Te Temperature (optional) AE Acoustic Emission (optional)
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Non-Rotating Pin-on-Flat Test Method: This test method involves a pin upper specimen that slides against an abrasive surface on a lower yaxis stage. While the lower stage is stationary, the pin is slid across the abrasive surface with the xaxis stage. At the end of each x-axis stroke the y-axis stage moves the width of the pin toward the rear. The x-axis stage reverses direction, and the sequence is repeated until the entire abrasive surface has been covered. The wear track of the pin is continuous and non-overlapping . The maximum travel of the x and y-axis stages is 75mm, which corresponds to a coverage area of 5625 mm. For nonoverlapping tracks with a width of 6.35 mm, the maximum length of the wear track is thus 807 mm (10 tracks X 75mm in the x direction plus 9 tracks X 6.35mm in the y direction). The maximum velocity of the x and y-axis stages is 10 mm/sec. UMT Hardware Configuration for Non-Rotating Pin-onFlat: 4 Mounting Block PN M30C116 Model DFH-10 Dual Friction/Load Sensor - range 1 N to 100 N Suspension with Linear Guide-AM30C110D-2 1/4 Pin Holder AM30B264B - for sensors mod. DFH 416 Stainless Steel Pin, Dia. 1/4, Length 0.5 - PN BM110006 Abrasive Sheet with Adhesive Backing Lateral Positioning and Sliding Drive - Mod. LWY-M Optional Additional Sensors - mod AE-5 Acoustic Emissions Sensor - mod. TMR-150 Temperature Measurement & Recording - mod. RTD Temperature Sensor
UMT Software Test Setup for Non-Rotating Pin-on-Flat: UMT Options File: Load the options file that contains settings for the Lateral Positioning and Sliding Drive and the 100 N force/load sensor. Use the Semi-Automatic Mode to pre-position the x-axis stage so that the pin is 5 mm from the right hand edge of the abrasive sheet. Pre-position the y-axis stage so that the pin is 5 mm from the back edge of the abrasive sheet. This will be the start of a non-overlapping wear track with a length of 0.807 m. Test Sequence: The Test Sequence should consist of 20 sheets. Sheet 1 is for settling time for the carriage to establish the initial normal load. Carriage - applies a -67 N Constant Force for a Duration of 10 sec. Spindle Velocity is 0 revs/min. Stage is idle. 15 YEARS OF LEADERSHIP IN MECHANICAL AND TRIBOLOGY TEST INSTRUMENTATION
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Sheet 2 moves the pin from right to left 75mm. Carriage - applies a -67 N Constant Force for a Duration of 7.5 seconds. Spindle Velocity is 0 rev. /min, Move-Continuous, and Direction- Clockwise Stage Working Velocity is 10 mm/sec., Initial Positioning Velocity is 2 mm/sec., and Position is Increment Offset 75 mm., Check Move Immediately, Direction Left. Sheet 3 moves the pin from back to front 6.35mm. Carriage - applies a -67 N Constant Force for a Duration of .635 seconds. Spindle Velocity is 600 rev. /min, Move-Increment, Distance 6.35 rev. and DirectionClockwise Stage is idle Sheet 4 moves the pin from left to right 75mm. Carriage - applies a -67 N Constant Force for a Duration of 7.5 seconds. Spindle Velocity is 0 rev. /min, Move-Continuous, and Direction- Clockwise Stage Working Velocity is 10 mm/sec., Initial Positioning Velocity is 2 mm/sec., and Position is Increment Offset 75 mm., Check Move Immediately, Direction right. Sheet 5 moves the pin from back to front 6.35mm. Carriage - applies a -67 N Constant Force for a Duration of .635 seconds. Spindle Velocity is 600 rev. /min, Move-Increment, Distance 6.35 rev. and DirectionClockwise Stage is idle Repeat sheets 2 through 5 three more times, and then sheets 2 through 4 one time by doing copy and paste for a total of 20 sheets. Data Collection: The following should be checked under DataFile: Fx Friction Force Fz Normal Force T Time Z1 Carriage Position (Used to determine Wear Depth) Te Temperature (optional) AE Acoustic Emission (optional)
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Rotating Pin-on-Flat Test Method: This test method involves a rotating pin upper specimen that slides against an abrasive surface on a lower y-axis stage. While the lower stage is stationary, the pin is slid across the abrasive surface with the x-axis stage. At the end of each x-axis stroke the y-axis stage moves the width of the pin toward the rear. The x-axis stage reverses direction, and the sequence is repeated until the entire abrasive surface has been covered. The wear track of the pin is continuous and non-overlapping . The maximum travel of the x and y-axis stages is 75mm, which corresponds to a coverage area of 5625 mm. For non-overlapping tracks with a width of 6.35 mm, the maximum length of the wear track is thus 807 mm (10 tracks X 75mm in the x direction plus 9 tracks X 6.35mm in the y direction). Because the pin is rotating the wear should be greater than the non-rotating. The maximum velocity of the x and y-axis stages is 10 mm/sec. Because the pin is rotating the wear should be greater than nonrotating. UMT Hardware Configuration for Rotating Pin-on-Flat: Model USMHH Upper Rotational Drive Model DFH-10 Dual Friction/Load Sensor (internal to Upper Rotational Drive) - range 1 N to 100 N Suspension with Linear Guide-AM30C110D-2 1/4 Pin Holder AM30B264B - for sensors mod. DFH 416 Stainless Steel Pin, Dia. 1/4, Length 0.5 - PN BM110006 Abrasive Sheet with Adhesive Backing Lateral Positioning and Sliding Drive - Mod. LWY-M Optional Additional Sensors - mod AE-5 Acoustic Emissions Sensor - mod. TMR-150 Temperature Measurement & Recording - mod. RTD Temperature Sensor
UMT Software Test Setup for Rotating Pin-on-Flat: UMT Options File: Load the options file that contains settings for the Lateral Positioning and Sliding Drive for spindle 1, and the Upper Rotational Drive with internal 100 N force/load sensor for spindle 2. Use the Semi-Automatic Mode to pre-position the x-axis stage so that the pin is 5 mm from the right hand edge of the abrasive sheet. Pre-position the y-axis stage so that the pin is 5 mm from the back edge of the abrasive sheet. This will be the start of a non-overlapping wear track with a length of 0.807 m. Because the pin is rotating, its wear is typically greater than that in the previous non-rotating pin test.
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Test Sequence: The Test Sequence should consist of 20 sheets. Sheet 1 is for settling time for the carriage to establish the initial normal load. Carriage - applies a -67 N Constant Force for a Duration of 10 sec. Spindle1 Velocity is 0 revs/min. Spindle2 Velocity is 0 revs/min. Stage is idle. Sheet 2 moves the pin from right to left 75mm. Carriage - applies a -67 N Constant Force for a Duration of 7.5 seconds. Spindle1 Velocity is 0 rev. /min, Move-Continuous, and Direction- Clockwise Spindle2 Velocity is 20 rev. /min, Move-Continuous, and Direction- Clockwise Stage Working Velocity is 10 mm/sec., Initial Positioning Velocity is 2 mm/sec., and Position is Increment Offset 75 mm., Check Move Immediately, Direction Left. Sheet 3 moves the pin from back to front 6.35mm. Carriage - applies a -67 N Constant Force for a Duration of .635 seconds. Spindle1 Velocity is 600 rev. /min, Move-Increment, Distance 6.35 rev. and DirectionClockwise Spindle2 Velocity is 20 rev. /min, Move-Continuous, and Direction- Clockwise Stage is idle Sheet 4 moves the pin from left to right 75mm. Carriage - applies a -67 N Constant Force for a Duration of 7.5 seconds. Spindle1 Velocity is 0 rev. /min, Move-Continuous, and Direction- Clockwise Spindle2 Velocity is 20 rev. /min, Move-Continuous, and Direction- Clockwise Stage Working Velocity is 10 mm/sec., Initial Positioning Velocity is 2 mm/sec., and Position is Increment Offset 75 mm., Check Move Immediately, Direction right. Sheet 5 moves the pin from back to front 6.35mm. Carriage - applies a -67 N Constant Force for a Duration of .635 seconds. Spindle1 Velocity is 600 rev. /min, Move-Increment, Distance 6.35 rev. and DirectionClockwise Spindle2 Velocity is 20 rev. /min, Move-Continuous, and Direction- Clockwise Stage is idle Repeat sheets 2 through 5 three more times, and then sheets 2 through 4 one time by doing copy and paste for a total of 20 sheets. Data Collection: The following should be checked under DataFile: Fx Friction Force Fz Normal Force T Time Z1 Carriage Position (Used to determine Wear Depth) Te Temperature (optional) AE Acoustic Emission (optional)
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Calibration Procedures
6.1 Force Sensor Calibration Procedure

All sensors are factory calibrated, and an option file containing the calibrated values is created for each sensor. If that file is lost or corrupted the following methods may be used to restore the file. 1. Disconnect the sensor cable and remove the sensor from the UMT, and reconnect it using the extension cable. 2. Install a holder capable of supporting the calibration weight to be used and place the sensor on a level, flat surface, holder side up. 3. Click on the Graphs Panel button. and Fz The Automatic Panel should appear displaying the default Fx
4. Click on the Semi-Automatic Panel button. Select the Data-1 tab
The Semi-Automatic Panel will appear.
and click on the 1111 button to un-bias the sensor.
5. Adjust the Fz pot through the opening in the panel on the carriage to obtain a value of 0 for Fz as displayed at the right side of the Automatic Panel. 6. Place the calibration weight on the holder as shown below and note the reported value displayed at the right side of the Automatic Panel.
Note:
For DFH and DFM sensors mounting before Fx calibration please refer to 15. and 16. below.
Fz Weight Placement
Fx Weight Placement
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7. Close the Automatic Panel and go to Options, Edit, then select Data Acquisition, Channels, Fz and note the value in the Scale +/-box.
8. Perform the following calculation: (AV / MV) * OS = NS Where: AV=Actual Value of the calibration weight being used MV= the Measured Value from the Automatic Panel OS = Old Scale Value taken from the Scale +/- window in the Option file NS = New Scale Value to be entered in the Scale +/- window. Do not use the () when performing the calculations. Example: In a UMT with a 500 g sensor (DFM-0.5) where the Scale +/- value (Old Scale) value was previously set at 497, and a 400 g calibration weight reports a value of 402 g, the formula would be (400 / 402) * 497= 494.5 which is the New Scale value to be entered in the Scale +/- window. Click Options, Save as to overwrite the Option file for this sensor and to save the new values. Note: Scale should be 1 for standard 2-D (Fx and Fy) sensors and offset should be zero. 9. See the figure above for proper weight placement to adjust Fx. 10. Before attaching the weight, adjust the Fx pot for 0 N. 11. Repeat steps 4 through 7 to complete Fx calibration.
Note:
For DFH and DFM sensors mounting before Fx calibration please refer to 15. and 16. below. 12. Repeat step 8 and enter the New Scale value for Fx into the Fx Scale+/- box. Click Options, Save as to overwrite the Option file for this sensor and save the new values. Note: Scale should be 1 for standard 2-D (Fx and Fy) sensors and offset should be 0. 13. Install the sensor in the UMT. 14. Adjust the Fx and Fz pots to within 3% of zero. Use the Bias All button to zero sensors before starting tests.
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15. DFM Sensor mounting for Fx calibration: Heavy duty carpenters clamps (2 pcs) DFM Sensor being calibrated. Make sure that only 4 Extension Block is placed on the supporting table but NOT the Sensor
4 Extension Block
Sensor Extension Cable (plugs in into the regular Fx, Fz cable)
Calibration weight (approx. 75% of full scale of the sensor)
Calibration Fixture for DFM Sensors Rigid Adapter for DFM Sensors
16. DFH Sensor mounting for Fx calibration: Heavy duty carpenters clamps ( 2 pcs) Calibration weight (approx. 75% of full scale of the sensor)
DFH Sensor being calibrated. Make sure that only 4 Extension Block is placed on the supporting table but NOT the Sensor Sensor Extension Cable (plugs in into the regular Fx, Fz cable)
Calibration Fixture for DFH Sesnors
Rigid Adapter for DFH Sensors Rectangular Suspension Page 88
7. Six-dimensional Sensor (6D) System Setup

Before running a test where the COF for torque (T-COF) is to be measured, use the Semiautomatic Panel to position the slider so that the upper specimen is located over the center of rotation of the lower specimen.
Once the slider is in the test position enter the radius for the calculation of COF of torque in the Distance window, then click on the Set Distance button. The radius should appear in the Position window.
Page 89

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CETR UMT Multi-Specimen Test System

Hardware Installation & Applications Manual

15 YEARS OF LEADERSHIP IN MECHANICAL AND TRIBOLOGY TEST INSTRUMENTATION

CETR UMT Multi-Specimen Test System

Hardware Installation & Applications Manual

15 YEARS OF LEADERSHIP IN MECHANICAL AND TRIBOLOGY TEST INSTRUMENTATION

CETR UMT Multi-Specimen Test System

Hardware Installation & Applications Manual

3 UMT System Installation and Setup _________________________________________________ 8

4 Typical Test Procedures __________________________________________________________ 27

15 YEARS OF LEADERSHIP IN MECHANICAL AND TRIBOLOGY TEST INSTRUMENTATION

CETR UMT Multi-Specimen Test System

Hardware Installation & Applications Manual

4.6.1 4.6.2 4.6.3

4.7.1 4.7.2 4.7.3 4.7.4 4.7.5 4.7.6

5 Application Notes for Various ASTM Tests __________________________________________ 58

6 Calibration Procedures __________________________________________________________ 86

Six-dimensional Sensor (6D) System Setup _________________________________________ 89

15 YEARS OF LEADERSHIP IN MECHANICAL AND TRIBOLOGY TEST INSTRUMENTATION

CETR UMT Multi-Specimen Test System

Hardware Installation & Applications Manual

CETR UMT Multi-Specimen Test System

Hardware Installation & Applications Manual

CETR UMT Multi-Specimen Test System

Hardware Installation & Applications Manual

15 YEARS OF LEADERSHIP IN MECHANICAL AND TRIBOLOGY TEST INSTRUMENTATION

CETR UMT Multi-Specimen Test System

Hardware Installation & Applications Manual

15 YEARS OF LEADERSHIP IN MECHANICAL AND TRIBOLOGY TEST INSTRUMENTATION

CETR UMT Multi-Specimen Test System

Hardware Installation & Applications Manual

15 YEARS OF LEADERSHIP IN MECHANICAL AND TRIBOLOGY TEST INSTRUMENTATION

CETR UMT Multi-Specimen Test System

Hardware Installation & Applications Manual

15 YEARS OF LEADERSHIP IN MECHANICAL AND TRIBOLOGY TEST INSTRUMENTATION

CETR UMT Multi-Specimen Test System

Hardware Installation & Applications Manual

15 YEARS OF LEADERSHIP IN MECHANICAL AND TRIBOLOGY TEST INSTRUMENTATION

CETR UMT Multi-Specimen Test System

Hardware Installation & Applications Manual

15 YEARS OF LEADERSHIP IN MECHANICAL AND TRIBOLOGY TEST INSTRUMENTATION

CETR UMT Multi-Specimen Test System

Hardware Installation & Applications Manual

15 YEARS OF LEADERSHIP IN MECHANICAL AND TRIBOLOGY TEST INSTRUMENTATION

CETR UMT Multi-Specimen Test System

Hardware Installation & Applications Manual

Suspensions, Adapters, and Upper Specimen Holders

15 YEARS OF LEADERSHIP IN MECHANICAL AND TRIBOLOGY TEST INSTRUMENTATION

CETR UMT Multi-Specimen Test System

Hardware Installation & Applications Manual

15 YEARS OF LEADERSHIP IN MECHANICAL AND TRIBOLOGY TEST INSTRUMENTATION

CETR UMT Multi-Specimen Test System

Hardware Installation & Applications Manual

0.5 Y-direction Positioning Attachment

Lower Specimen Motorized Drives and Tables

15 YEARS OF LEADERSHIP IN MECHANICAL AND TRIBOLOGY TEST INSTRUMENTATION

CETR UMT Multi-Specimen Test System

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15 YEARS OF LEADERSHIP IN MECHANICAL AND TRIBOLOGY TEST INSTRUMENTATION

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Model R35HE with Integrated Lateral Sensors

15 YEARS OF LEADERSHIP IN MECHANICAL AND TRIBOLOGY TEST INSTRUMENTATION

CETR UMT Multi-Specimen Test System