1. Project & presntion Supervisor : dr.Alaa mOHAMED
Oil Testing Machine
Project & presntion
Supervisor : dr.Alaa mOHAMED

2. * Introduction:
* In essence this experiment seeks the effects of forces and stresses on metals since these forces transform from static forces in the form of weights into friction forces that affect the metal due to motion. These forces are analyzed (force and strength analysis) and mathematically calculated. 
* The purpose of this project is to identify the quality of oils used in cars and machines, and to categorize metals according to their ability to resist friction and stresses without causing corrosion in a short period of time.
* This experiment can also be used to calculate the amount of energy caused from friction between metals.

3. The machine used in this test has many names such as:
* (Oil Test Machine)
* ( Oil Strength Test Machine)
* ( Oil Friction Test Machine)
* (Timken Friction Test Machine )
This test is described by many others names such as :
* (Metal Friction Test)
* (Oil Test )

4. * Oil and its properties: Oils: oils are any non polar fluid viscose substance at room temperature of slightly higher temperatures, these oils are known to be water repellent and interactive with fats. * Types of oils: Oils have three types according to their composition: 1- Metallic oils. 2- Synthetic oils. 3- Semi-synthetic oils. 

5. * Metallic oils: * General properties of metallic oils:
Is extracted from petrol after recycling and purifying it.
* General properties of metallic oils:
1) Enough viscosity to ease the sliding of mechanical parts in machines in different stress conditions and with minimum energy loss.
2) Suitability for engine performance and moving parts in different weather conditions especially in extreme cold conditions.
3) They have the ability to clean the friction residue from moving parts in engines and machines.
4) They have the ability to resist corrosion and oxidation.
5) The consideration of industrial and environmental safety and not to have poisonous compounds.

6. * Synthetic oils:
They are oils that are chemically modified in labs to develop properties which differ from metallic oils properties. 
* Properties of synthetic oils:
1) chemical and physical stability compared to metallic oils it doesn't dissolve or lose its viscosity quickly.
2) minimizes friction extremely which can be noticed when compared to metallic oils.
3) constant viscosity both in low and high temperatures.
4) since its viscosity is constant its flow speed is higher than that of the metallic oil which helps to do the oiling efficiently.
5) longer life, and less evaporating rate when compared to metallic oils.
6) high performance in extremely high or low temperatures.

7. * Semi-synthetic oils:
Is a mixture of both synthetic and metallic oils in which the concentration doesn't exceed 30%.

8. * Different working conditions of oils:
Oil is directly affected by its surrounding conditions, heat and moisture and machine operating systems all determine the suitable oil for usage in these conditions, these conditions change with time and place and type of machine and its design and its purpose. Internal combustion engine oils in automobiles and heavy equipments, frigate oils and airplane oils all share similar characteristics unlike oils used in turbines and electrical generators and transformers and resistors and motion transfer oils and steam turbine oils, they each have special oils that differ in their properties, viscosity , and density, along with other factors to coincide with the surrounding working conditions and its usage.

9. * Oil processing (oil additives):
Additive materials were made for oils with the purpose of increasing their viscosity and minimize friction inside machines and gear shifts and to increase life. They are added with machine oils with 5% concentration and they are uncommon.
* Choosing oil according to viscosity:
The (API) and (SEA) systems are the most commonly used for determining the type of oil for machines.

10. * Society of Automotive Engineers (SAE):
This classification was established in 1911 and it is an international classification to determine only the viscosity of oils, and has nothing to do with determining the quality of oils or their usage in certain machines.
* Winter viscosity classes are:
(0W ,5W, 10W, 15W, 20W, 25W ) SAE.
* Summer viscosity classes are:
( 20, 30,40,50,60 ) SAE.
* The meaning of the symbols on oil boxes:
For example: SAE 10W-40
SAE 40: summer viscosity has a value of (40) which means that the oil can be used in the summer in temperatures between (40-45) degrees.
SAE 10W: viscosity in winter which is referred to with (w) means that oil can be used in temperatures between (10-15) degrees.

11. Testing of various oils to determine their density and flow speed at 35 degrees and for 16 hours.
A chart that clarifies the different classes of oils and their suitability to function in different temperatures.

12. *( American Petroleum Institute )( API):
This classification was established in 1947, which is a classification that does not only determine the viscosity of oils it determines their quality and operating properties. 
* Other classifications of oils:
1) (European Automobile Manufacturers Association) (ACEA).
2) (International Lubricant Standardization and Approval Committee )
( ILSASC).

13. *Friction: * Concept of friction in metals:
Friction forces are classified into two categories:
1- Static Of Frication:
fs = μs N
2- Kinetic Of Friction
fk = μk N 
* Concept of friction in metals:
Friction is the resistance of motion that occurs due to contact between two solid bodies. 
When examined under a microscope a metal is seen as a group of particles these particles collide with one another and cause wear in metals which is called (metal friction).

14. * Damages of friction between machines and metals:
1) The energy caused by friction is converted into excessive thermal energy that deforms metals and increases corrosion.
2) A massive waste in energy through converting it into thermal energy which decreases the efficiency of machines.
3) Friction causes melting in some materials which leads to complete deformation.
4) Machines become flawed and lose their ability to endure and operate.
5) Operating life of machines decreases and they become outdated.

15. (μ) (Coefficient Of Friction):
Coefficient of friction is an expression of the numerical value indicating the amount of forces created between two bodies due to friction and is used to indicate the pressure force between two bodies in friction, it has no unit and cannot be calculated using mathematical relations and measuring it depends only on experiment. 
Every couple of surfaces that cause friction no matter what type of material they are made of have their own coefficient of friction. This table shows the coefficient of friction of different metallic surfaces.

16. * Calculation of friction force:
Friction force caused in this experiment is kinetic friction.
fk = μk N

17. Timken Bearing Frication Test Machine:
Machine made by a company (commercial production)
Illustration of the testing machine through solidworks.

18. * Mechanical function and definition:
A machine that is used to conduct a friction test for a sample of metal in an oil medium to measure friction through the working of specific forces these forces take the form of weights with known values these forces and analyzed and calculated.

19. * Advantages of friction test:
1- Analyzing and calculating forces and stresses which affect the metal. 2- Measuring of energy output caused by friction. 3- Identifying the type of oil suitable for the machinery regarding quality and operational properties. 4- Differentiating between metals in its ability to resist friction and stresses.

20. * Parts of the testing machine:
1- Machine base:
On which the machine is mounted and assembled it is usually of metallic nature (Iron , Steel , Aluminum) and designed in a specific shape.
C base
Flat base

21. *2- Electric Motor: *3- (Heavy Duty Bearing ) Bearing:
Is basically a loading base equipped with a bearing and a smooth rod shaft passes through it, it carries the shaft and minimizes friction.
It is mounted on the base of the machine using bolt screw .
*2- Electric Motor:

22. *4- Pulley Belt: They are used for motion transmission from the motor to the shaft.
The velocity of the driver pulley wheel is greater than the velocity of the driven pulley.

23. The Timken testing machine posses two pulleys:
A- Driver pulley wheel: Mounted on the shaft coming out of the electric motor and it must be of a small diameter in order to achieve higher rpm. It is mounted on the shaft using bolt screws
B-Driven pulley:
Mounted on the smooth rod shaft and it has a larger diameter than the driver pulley and its diameter is inversely proportional with the rpm of the shaft.

24. *5- Belt drive: A way of transmitting motion between the two pulleys and is made of rubber.

25. 6- The test sample rod: A piece of metal of a rectangular shape with a small cavity in the front in the form of a rectangular. The sample is installed inside that cavity using a bolt screw and has a hole to fix the rod on the body of the machine.

26. 7- The weight rod:
Is a rectangular piece of metal that has two holes one to fix it on the machine and the other is to hang weights from.
8- Oil box:
It is filled with testing oil, it is to ensure the constant oiling of the sample.

27. 9- Pins rod:
Is put in a piece of metal fixed on the machine base and is used to fix the weight rod and the sample rod.
10-Weights:
They need to be of known and equal values.

28. 11- Friction wheel:
It needs to be of high hardness steel so it doesn't fail during the friction test.

29. * Testing process: 1) Supply a sample of metal with smooth surface.
2) Measuring dimensions of sample using vernier caliper.
3) Fixing the sample in the sample rod using a bolt screw.
4) Fill the oil box with the oil to be tested.
5) Fixing the sample rod on the body of the machine and making sure it is in contact with the friction wheel.
6) Gradually hanging weights on the weight rod.
7) When increasing the weights on the sample to a larger stress than the motor can take it will stop completely.
8) Observe the effect of friction on metals with the naked eye and comparing it between a number of samples with different loads and different types of oils.
9) Calculating loads and stresses using the following laws.

30. * Timken Load Calculation:
Calculating loads and stresses using the following laws :
The load is calculated on a small sample of metal using the following law :
(( Loading Wight ( unit : lb ) / ( Length X Width (mm))

31. * Photos of the project after implementation:
The machine after final assembly
Heavy Duty Bearing & Shaft

32. Driver pulley wheel & Belt
Driven pulley & Belt

33. Electric Motor
Shaft & Heavy Duty Bearing

34. The test sample rod & Oil Box & Friction wheel & Sample test
Weights

35. The weight rod