Running head: MATERIALS DURABILITY ANALYSIS TEST 1

Test Procedure: Materials Durability Analysis Test

Group 2

Babcock, Chaisson, Clark, Fitzell, Urrea, Xue

Severna Park High School

17 March 2019
TEST PROCEDURE 3 2

Table of Contents

Materials Durability Analysis 3

Authors 3
Group Members 3
Testing Date 3
Testing Location 3
Purpose 3
Initial Conditions 3
Materials 3
Pass or Fail Criteria 4
Pass. 4
Fail. 4
Procedures 4
Safety Considerations 5
Data 5
Data Collection Graph 5
Data 5
Results 5
Discussion of Results 5
Expert Feedback 5
Recommendations 6

Appendix C 7
TEST PROCEDURE 3 3

Materials Durability Analysis

Authors

Virginia Babcock, Group 2

Group Members

Alex Chiasson, Garrison Clark, Mary Fitzell, Josie Urrea, and Feiyu Xue

Testing Date

3/20/19

Testing Location

115 Boone Trail, Severna Park, MD, 21146

Purpose

To determine the length of time that the components of the braking system are able to

function without breaking.

Initial Conditions

Ensure calculator is in working condition.

Materials

● Paper

● Pencil

● Calculator

● Equations (See Appendix C, Instructions A.)

● Variable list (See Appendix C, Table A.)

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Pass or Fail Criteria

Pass.

Pieces are able to function for 6 or more years.

Fail.

Pieces are unable to function for 6 or more years.

Procedures

1. Use the derived time equation (Refer to Appendix C, Instructions A.)

2. Find the Young’s Modulus (E) value for the ring-track interaction (Refer to Appendix C,

Table B.). Plug value in for the “E” variable in the derived equation.

3. Find the sliding distance (d) for the ring-track interaction (Refer to Appendix C, Table

B.). Plug value in for the “d” variable in the derived equation.

4. Solve for t, the time in seconds that the part interaction will function. Record raw time in

table (Refer to Appendix C Test Data, Table C.).

5. Divide the raw time by 31,536,000 to determine the number of years that the part will be

operational. Record in table (Refer to Appendix C Test Data, Table C.) and determine if

that data passes (6 years or above) or fails (below 6 years).

6. Repeat calculations with lever-pivot interaction then with brake pad, and record in table

(Refer to Appendix C Test Data, Table C.).

Safety Considerations

Not Applicable.
TEST PROCEDURE 3 5

Data

The test will produce quantitative data, measuring the length of time, in years, that a

piece can function.

Data Collection Graph

Refer to Appendix C Test Data.

Data

Refer to Appendix C, Table A. and Table B., and Appendix C Test Data.

Results

Pass. The ring-track interaction is predicted to function for over 6 years, with a predicted value

of 40.13 years.

Fail. The lever-pivot interaction, and the brake pads are predicted to function for under six years.

The lever-pivot interaction is predicted to function for 1.7835 years without wearing out. The

brake pad is predicted to last for 0.4206 years without wearing out.

Discussion of Results

The data obtained from the tests indicated some part interactions would be able to sustain use for

lengths of time far exceeding the designated 6 years amount, which other parts fell very short.

The test is repeatable, and the data is of good quality but it is possible that confounding variables

could have been left unnoticed, possibly changing the outcomes. Some measurements taken that

were used for the data could have been slightly off, as some of the numbers are very small and

difficult to make accurately.

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Expert Feedback

● Using a material like PTFE or a similar low friction material could help increase the

lifetime of the lever-pivot interaction

● Brake pads could potentially be made of a more durable material, or could be more easily

replaceable in order to counteract the short lifespan

Recommendations

In order to improve the overall quality of the data, it could be beneficial to use multiple different

equations to solve for time, then compare results to create more heavily tested, theoretically more

accurate, data. Another test that was considered, but was not feasible, was a physical lab test of

the parts using a physical prototype which would be put under machine-simulated conditions to

model the passage of time until the parts wore out. Unfortunately, a physical prototype that had

the correct materials necessary could not be completed within the timeframe once the overall

design was finalized, and would not be practical for the project. In terms of product design, the

lever-pivot interaction may require use of different materials in order to create the longevity

necessary. For the brake pads, more frequent replacement may be necessary, but because they

are fairly inexpensive and simple to replace, this should not be a huge maintenance issue.
TEST PROCEDURE 3 7

Appendix C

Instructions A.
Equation Derivation
(K)(F load )
1. w = E
ΔW
( (F )F load
load )(d)(ρ) ΔW
2. w = E
Plug in equation K = (F load )(d)(ρ)
.

(ΔW )(F load )

3. w = (ρ)(E)(F load )(d)

ΔW
4. w = (ρ)(E)(d)
Simplify.

ΔV ΔW ΔV
5. t
= (ρ)(E)(d)
Plug in equation w = t
.

t (ρ)(E)(d)
6. ΔV
= ΔW
Take the inverse of the equation.
(ρ)(E)(d)(ΔV )
7. t = ΔW
Simplify.
(ρ)(E)(d)(ΔV )
8. t = (Δm)(g)
Plug in equation ΔW = (Δm)(g) .

(ρ)(E)(d)( Δm
ρ ) Δm
9. t = (Δm)(g)
Plug in equation ΔV = ρ
.
(E)(d)
10. t = g
Simplify.
(E)(d)
11. t = 9.8 m2
Plug in constants. This is the final derived equation.
s

Table A.

d = Sliding distance E = Young’s F load = Load force g = Acceleration due

Modulus to gravity (constant
9.8 sm2 )

K = Specific wear Δm = Mass of ρ = Density ΔV = Change in

rate material material volume

w = Wear rate ΔW = Change in t = Time

weight of material
(Note: Variables and constants are outlined here.)

Table B.
TEST PROCEDURE 3 8

Part Interaction Material(s) Young’s Modulus Sliding distance (m)

(Pascals)

Ring-track Aluminum 6061 6.89 × 1010 0.18

Lever-pivot PTFE 2.35 × 1011 0.008

Brake pad Rubber 1 × 109 0.13

Image A.

(Note: Ring-track interaction depiction)

Image B.
TEST PROCEDURE 3 9

(Note: Lever-pivot interaction depiction)

Appendix C Test Data
Table C.

Model Part Raw value of t (s) Conversion of t 6 or more years?

Interaction t = (E)(d)
g
(years) (Pass)
t
# of years = 31536000 Less than 6 years?
(Fail)

Ring-Track 1,265,510,204 40.13 Pass

Lever-Pivot 191,836,734 6.083 Pass

Brake Pad 132,653 0.4206 Fail