FABRICATION AND ANALYSIS OF PIN ON DISC

TRIBOMETER FOR LUBRICATED ENVIRONMENT

A PROJECT REPORT

Submitted by

PRIYESH S (Reg. No. 2127221001025)

ROHITH KRISHNA N (Reg. No. 2127221001026)
SAI SANTHOSH J (Reg. No. 2127221001027)

in partial fulfillment for the award of the degree

of

BACHELOR OF ENGINEERING

IN

MECHANICAL ENGINEERING

SRI VENKATESWARA COLLEGE OF ENGINEERING

(An Autonomous Institution; Affiliated to Anna University)
ANNA UNIVERSITY :: CHENNAI 600 025
MAY 2026
 SRI VENKATESWARA COLLEGE OF ENGINEERING
(An Autonomous Institution; Affiliated to Anna University)
ANNA UNIVERSITY, CHENNAI 600 025

BONAFIDE CERTIFICATE

Certified that this project report “FABRICATION AND ANALYSIS OF PIN ON

DISCTRIBOMETER FOR LUBRICATED ENVIRONMENT” is the bonafide work of
“ PRIYESH S (2127221001025), ROHITH KRISHNA N (2127221001026) and SAI
SANTHOSH J (2127221001027) ” who carried out the project work under our supervision.

SIGNATURE SIGNATURE
Dr. S. RAMESH BABU Dr. R. RAMESH
HEAD OF THE DEPARTMENT SUPERVISOR
Professor Associate Professor
Department of Mechanical Engineering Department of Mechanical Engineering

Submitted for the project viva-voce examination held on _______________

INTERNAL EXAMINER EXTERNAL EXAMINER

 DESIGN AND FABRICATION OF PIN ON DISC
TRIBOMETER FOR LUBRICATED ENVIRONMENT

Abstract:

• This project involves the design and development of a pin-on-disc

lubricating setup to evaluate the tribological performance of machined
components under dry and lubricated conditions.

• The setup incorporates an enlarged disc, adjustable pin mechanism,

controlled lubrication delivery system, and integrated load cell for real-
time monitoring of the developed friction parameters.

• Data acquisition enables measurement of frictional force, wear rate, and

traction behavior under varying loads, sliding speeds, and lubricant types.

• Preliminary work includes fabrication of the lubrication system, motor

speed verification, and wear rate calculations.

• The study aims to address gaps in existing tribological test methods by

simulating realistic traction operating conditions, thereby supporting
improved material selection and lubricant assessment for industrial
applications such as gears, bearings, and sliding elements.

i
 ACKNOWLEDGEMENT

First and fore-most we owe heartfelt thanks to our parents for their
blessing and their encouragement to do this project successfully. We
express our heartfelt thanks to the management of

“SRI VENKATESWARA COLLEGE OF ENGINEERING” for

providing us the platform for the project work.

We sincerely thank Dr. R. RAMESH, Associate Professor,

Department of Mechanical Engineering, for his valuable guidance,
clarification and encouragement to accomplish this project.

We express our profound thanks to Dr. S. RAMESH BABU, Professor &

Head of the Department, Mechanical Engineering for encouraging us in
doing this project.

We also take this opportunity to thank the project coordinators

Mr. S. NATRAJAN, Associate Professor Department of Mechanical

Engineering, for their suggestions and constructive criticisms.

We also wish to express our sincere thanks to all teaching and nonteaching
staff members of the Department of Mechanical Engineering and our
friends for their kind help during the course of the study.

PRIYESH S
ROHITH KRISHNA N
SAI SANTHOSH J

ii
 TABLE OF CONTENTS

CHAPTER NO. TITLE PAGE NO.

Abstract: i
LIST OF FIGURES v
LIST OF SYMBOLS AND ABBREVIATIONS vii

1 Introduction

1.1 Problem Statement 3

1.2 Problem Definition 3

1.3 Aim 4

1.4 Objective 4

1.5 Application of the System 5

1.6 Challenges and Considerations 6

2 Literature Review

2.1 Project Background 8

2.2 Summary of the Literature Review 9

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3 CLASSIFICATION OF TRIBOMETERS

3.1 Standard configuration tribometers 12

3.2 Based upon lubrication environment 13

3.3 Classification by loading mechanism 15

3.4 Classification by motion type 16

3.5 Classification by high tech features 18

4 Methodology of the system

4.1 Flow Chart 22

5 Design of the System

5.1 3D Model of the system 23

6 Design Calculation

6.1 Calculation 26

6.2 Calculation 27

6.3 Calculation 28

6.4 Calculation 28

6.5 Calculation 29

6.6 Calculation 30

6.7 Sensor Program 32

7 Components of the System

iv
 7.1 Different types of System 38

8 Fabrication Work

8.1 Metal Cutting Process 45

8.2 Machining Process 45

8.3 Drilling Process 46

8.4 Welding Process 46

8.5 Assembly of the Components 47

9 Experimental Setup

9.1 Conceptual process 48

9.2 Working Model of the system 49

9.3 Testing of the System 51

10 Overview of the System

10.1 Conclusions 52

10.2 Future Scope 54

10.3 Reference 55

LIST OF FIGURES

v
 PAGE
TITLE
NO
Disc (D3 material)
1.

Mild steel slab foundation

2.

Weighing plates (500g x 8)

3.

Speed control of DC Shunt motor

4.

LM guide way
5.

Lubricating Pump
6.

HX711 Amplifier
7.

Load cell
8.

ESP 32
9.

Buck converter
10.

vi
LIST OF SYMBOLS AND ABBREVIATIONS

SYMBOLS

[Link] Symbols Explanation

1. S Speed (Rpm)
2. P Power (Watts)
3. T Torque (Nm)
4. F Force (N)
5. H Hardness (HRC)
6. G Modulus of Rigidity (N/mm^2)
7. μ Coefficient Of Friction

vii
ABBREVIATIONS

[Link] Symbols
Explanation

1. Li-Po Li- ion Battery

2. UNO Arduino System

3. PM Power Module

4. MD Motor Drive

5. LC Load Cell

6. M Mass flow rate

7. COF Coefficient of Friction

8. MS Mild Steel

9. AL Aluminum

10. D3 Tool Steel (Disc)

11. SS304 Stainless Steel (Pin)

12. TiG5 Titanium Grade 5 (Pin)

viii
 CHAPTER-1

INTRODUCTION

Tribology is the multifaceted science of interacting surfaces in relative motion,

encompassing the study of friction, wear, and lubrication. In modern industrial
applications, the efficiency and longevity of mechanical systems—ranging from
automotive engines to heavy manufacturing equipment—are dictated by the
tribological performance of their components. It is estimated that approximately
20% of the world’s total energy consumption is spent overcoming friction, while
mechanical wear remains a primary cause of component failure and replacement.

Lubrication serves as the critical interface between sliding surfaces, designed to

minimize direct metal-to-metal contact. By introducing a lubricant, the system
can transition through various regimes—boundary, mixed, or hydrodynamic
lubrication—thereby reducing the Coefficient of Friction (COF). Understanding
how specific material pairs behave under lubricated conditions is essential for
optimizing industrial maintenance and energy efficiency.

The pin-on-disc tribometer is a globally recognized experimental setup for

characterizing the wear and friction properties of materials. Its design typically
involves a stationary pin loaded against a rotating disc, creating a controlled
environment to measure material loss and frictional resistance. This configuration
is favored in research and development due to its ability to simulate high-pressure
contact and its adherence to international standards, such as ASTM G99.

9
While dry tribological testing provides a baseline for material hardness and shear
strength, it often fails to replicate the complexities of real-world mechanical
environments where lubricants are present. Factors such as lubricant viscosity
(e.g., ISO VG grades), temperature stability, and film thickness significantly alter
wear mechanisms. There is a continuous need for accessible, high-precision
testing rigs that can evaluate the synergy between specific alloys and lubricants
to prevent catastrophic failure in industrial machinery.

II. PROBLEM STATEMENT

In recent times most commercially available tribometer set ups are cost-
prohibitive for many laboratory environments, and standard dry-testing rigs lack
the containment necessary for fluid analysis. This project aims to design and
fabricate a specialized pin-on-disc tribometer capable of operating in a lubricated
environment.

Project Definition:

This project is intended to design and fabricate a straightforward setup where

the experimental analysis can be carried out. The set up is equipped with load cell
sensors to detect frictional load experienced upon running and a provision for pin
with holder and disc with holder for contacting end. utilize that to determine
whether there was an issue with it or not. The project is vital to bridge the gap for
theoretical and practical need for accessible, high-precision testing rigs. These
setups can help evaluate the synergy between specific alloys and lubricants to
prevent catastrophic failure in industrial machinery.

10
AIM:

• The aim of this project is to design, fabricate, and validate a Pin-on-Disc

Tribometer capable of evaluating the friction and wear characteristics of
material pairs under lubricated conditions. The project focuses on creating
a reliable experimental setup to analyze the influence of lubricant viscosity
and applied load on the specific wear rate and coefficient of friction.

OBJECTIVE:

 To design a robust mechanical assembly capable of maintaining stable

contact between a pin and disc under varying vertical loads.
 To develop a lubrication housing or recirculation system that enables
testing under fully flooded or boundary lubrication conditions.
 To integrate a data acquisition system for the real-time monitoring of
frictional forces and wear depth.
 To evaluate the wear characteristics of specific metal specimens to
validate the rig's performance against established wear laws.

Applications of the system:

The applications of a lubricated pin-on-disc tribometer, emphasize that this
system is not just a laboratory tool, but a simulator for massive industrial
challenges.

Automotive Industry: The automotive sector is the largest consumer of

tribological data.

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  Engine Components: Simulating the contact between piston rings and
cylinder liners, or camshafts and followers, to minimize energy loss.
 Drivetrain & Gears: Testing the effectiveness of transmission fluids in
protecting gear teeth under high-pressure sliding contact.
 Brake Systems: Evaluating wear in wet-brake systems where friction
must be controlled despite the presence of hydraulic fluids.

Lubricant & Additive Development: This is perhaps the most direct

application for a lubricated rig.

 Viscosity Testing: Comparing the performance of different oil grades

(e.g., ISO VG 32 vs. ISO VG 68) under identical load conditions.
 Nano-additives: Testing the efficiency of modern "green" lubricants or
biolubricants and comparing them to traditional mineral oils.

Materials Science & Surface Engineering:

 Hard Coatings: Testing the durability of specialized coatings like

Diamond-Like Carbon (DLC) or TiN (Titanium Nitride) when submerged
in oil.
 Heat Treatment Validation: Determining how different hardening
processes (like nitriding or carburizing) affect the wear rate of steels like
D3 or Mild Steel.

Challenges and Considerations:

Mechanical Stability and Vibration Control:

 The integrity of tribological data depends on a "noise-free" environment.

12
  Challenge: High-speed rotation can induce vibrations that interfere with
the frictional force readings. If the frame is not rigid, the pin may
"chatter" or bounce on the disc.
 Consideration: To use a heavy, damped base (like cast iron or thick steel
plate) and ensure the motor is isolated from the loading arm using high-
quality couplings.

Precise Loading Mechanism:

 Challenge: Applying a perfectly vertical load is difficult. If the loading

arm is slightly tilted, it introduces lateral forces that skew the friction
data.
 Consideration: To use a dead-weight system with a balanced lever arm
or a pneumatic cylinder. Ensuring the "pin-to-disc" contact is perfectly
perpendicular as it is critical for uniform wear.

Lubricant Containment and Splashing:

 Challenge: At high RPMs, centrifugal force will throw the lubricant off
the disc. This creates a mess and, more importantly, leads to "starvation"
where the contact point dries out.
 Consideration: To design a specialized fluid reservoir (cup) that rotates
with the disc or a stationary enclosure with seals.

Friction Sensing and Data Acquisition:

 Challenge: The frictional force is often very small compared to the

applied vertical load. Measuring this small "tangential" force accurately
requires high sensitivity.

13
  Consideration: To use an load cell or a strain gauge mounted on the
stationary pin holder. The electronics must be shielded from
electromagnetic interference (EMI) from the motor.

Alignment and Run-out:

 Challenge: If the disc is not perfectly flat or level, or the shaft is slightly
bent (axial run-out), the pin will move up and down during every rotation.
This creates fluctuating loads.
 Consideration: The disc must be precision-ground and the mounting
flange must be machined to high tolerances. To use a dial indicator during
assembly to keep run-out within microns.

Material Selection for the Rig:

 Challenge: Lubricants can be corrosive or may contain additives that

react with certain metals. Furthermore, the rig itself must not wear out
faster than the specimens.
 Consideration: Use stainless steel (like SS304 or SS316) for parts in
contact with the lubricant to prevent rust. To ensure the pin holder is
significantly harder than the pins being tested to prevent deformation.

14
 CHAPTER 2

Literature Review for the project

In earlier studices, numerous investigations were performed on the wear

properties of various alloys using a tribological analysis. The alloys wear
behavior found that the wear rate greatly enhanced in relation to the application
of force. The Ti-alloy or any other alloy used in wear process contains four
different steps with a high-speed tribometer. The effect of sliding speed on the
maximum temperatures attained is incredibly minimal. The wear and friction
characteristics of surfaces are regulated by the impact of load, surface condition;
and oxidation are all linked to the sliding contact mechanism.

The amount of applied stress, the sliding speed, and the distance traveled while
sliding all have a significant impact on these variables. The novelty of this
research lies in exploring the effects of wear process parameters on wear mass
loss and co-efficient of friction using Titanium alloy and stainless steel alloy.

Most of researchers performed wear studies on pure alloys grade. It has found
that very few studies has found on wear behavior particularly titanium alloy grade
5 and stainless steel SS304 alloy. Hence there are needs for exploring wear
behavior using these factors. The objectives of this study are to analyze the wear
mass loss and CoF of Ti-alloy and Stainless steel alloy at various process
parameters and its level and comprehend the wear properties and surface
morphology of worn areas.

15
 CHAPTER-3

Classification of Pin on disc Tribometers

The most fundamental way to classify these machines is how the pin and disc
are oriented in space. This affects how gravity influences the wear debris and
how lubricants are maintained.

1.1 Vertical Configuration (Standard):

In the standard vertical setup, the disc rotates in a horizontal plane (like a record
player), and the pin is applied vertically from above.

 Advantages: Easiest to load using dead weights; gravity keeps the

lubricant on the disc surface.
 Use Case: Most common for dry and flooded lubrication tests.

1.2 Horizontal Configuration:

The disc rotates in a vertical plane (like a car wheel), and the pin is pressed
horizontally against the face.

 Advantages: Wear debris falls away from the contact zone, preventing
"third-body abrasion" (where old wear particles cause new scratches).
 Use Case: Studying pure material wear without the interference of
trapped debris.

1.3 Inverted Configuration:

The pin is held at the bottom, and the disc is pressed down onto it.

 Advantages: Useful for specific specialized sensors that need to be

mounted underneath the contact point.

2. Classification by Lubrication Environment:

Since your project is specifically about a lubricated environment, this is a
critical section for your report.

2.1 Dry Tribometers:

16
These operate in ambient air with no fluid interface.

 Focus: Fundamental material hardness and oxidation-driven wear.

2.2 Flooded/Submerged Tribometers

The disc and pin are entirely submerged in a lubricant bath.

 Design Requirement: Requires a "cup" or reservoir that rotates with the

disc.
 Application: Simulating deep-oil-sump conditions in gearboxes.

2.3 Boundary/Drip-Feed Tribometers:

Lubricant is supplied via a nozzle at a specific rate (drops per minute).

 Application: Simulating "starved" lubrication conditions where only a

thin film is present.

2.4 Recirculating Systems:

A pump circulates the oil from a reservoir to the contact point and back through
a filter.
 Application: Studying the effect of lubricant temperature and filtered vs.
unfiltered oil on wear.

3. Classification by Loading Mechanism:

How the "Normal Force" ($F_n$) is applied to the pin determines the accuracy
and dynamic range of the machine.

3.1 Dead Weight Loading:

A simple lever arm with physical weights.

 Pros: Constant force, highly reliable, no calibration needed.

 Cons: Can cause "bouncing" or vibrations at high speeds.

3.2 Pneumatic/Hydraulic Loading:

Force is applied via air or fluid pressure.

 Pros: Allows for "dynamic loading" (changing the weight during the
test).
 Cons: Requires a compressor and complex seals.

17
3.3 Electromagnetic/Actuator Loading:
Uses a linear motor to apply force.

 Pros: Extremely precise; can simulate "impact" or "vibratory" loads.

 Cons: Very expensive and requires complex control software.

4. Classification by Motion Type:

While "Pin-on-Disc" usually implies continuous rotation, there are variations in
the motion path.

4.1 Unidirectional (Continuous):

The disc spins in one direction at a constant or variable RPM. This is the
standard for calculating Archard's Wear.

4.2 Reciprocating (Oscillating):

The disc (or pin) moves back and forth in a linear or angular arc.
 Application: Simulating piston ring movement in an engine cylinder.

4.3 Spiral Path:

The pin moves radially (inward or outward) while the disc spins, creating a
spiral track.

 Application: Ensuring the pin always touches "fresh" material rather than
staying in the same groove.

5. Classification by High-Tech Features:

Modern tribometers are often classified by the additional variables they can
control.

5.1 High-Temperature Tribometers:

Equipped with heating elements (ovens) around the contact zone, often reaching
up to 1000°C.

 Application: Aerospace and turbine blade materials.

5.2 Vacuum/Inert Gas Tribometers:

The entire setup is inside a vacuum chamber or filled with Nitrogen/Argon.
18
  Application: Space applications where there is no oxygen to form
protective oxide layers.

5.3 Nano/Micro Tribometers:

Designed for extremely low loads (millinewtons) and very small pins (microns).

 Application: MEMS (Micro-Electro-Mechanical Systems) and thin-film

coatings.

6. Classification by Data Acquisition (DAQ):

How the machine "talks" to the user is a major differentiator in cost and quality.

 Manual Systems: Friction is measured using a simple spring balance or

by observing the deflection of a beam.
 Automated Systems: Use LVDTs (Linear Variable Differential
Transformers) for wear depth and Load Cells for friction force.

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 Chapter-4
METHODOLOGY OF THE PROJECT

Pin on disc tribometer for lubricated environment and analysis.

Design model and Design Calculations

Materials procurement

Fabrication of frame and components using Studying and implementation of control

required machining, welding and drilling systems and incorporating the load cell
processes. sensors in the setup along with other circuit
components.

It will control the DC motors for movement To use an Arduino control system to manage
and process the sensor data to allow the frictional load detection and sensors
frictional load detection. operation upon switching on the shunt motor
at fixed rpm

Using established setup for data collection for

Revise the acquired data from sensors
varying pin samples by using different loads.

20
 Chapter-5
DESIGN OF THE PROJECT
The design of pin on disc tribometer set up for lubricated set up is done using
Creo parametric software.

ISO View:

Front view:

Top view:

Bottom view:

21
 Chapter-6
Design Calculation

22
Sensor Program

23
 CHAPTER-7
COMPONENTS USED
The main components used in our project are listed below

1. Disc (D3 material)

2. Pin (TiG5 and SS304)
3. Mild steel slab foundation
4. Weighing plates (500g x 8)
5. Speed control of DC Shunt motor
6. LM guide way
7. Lubricating Pump
8. HX711 Amplifier
9. Load cell
10. ESP 32
11. Digital display
12. Buck converter

24
1. Disc (D3 Material): D3 is a high-carbon, high-chromium "Cold
Work" steel known for excellent wear resistance and hardness. In this
setup, it acts as the counter-face. Its durability ensures that the wear
measured is primarily on the pin, or that the disc can withstand thousands
of cycles without catastrophic failure.
2. Pin (TiG5 and SS304): These are your specimens.

TiG5 (Grade 5 Titanium): Offers high strength and corrosion resistance

but is prone to galling, making it an interesting subject for wear studies.

SS304 (Stainless Steel): A standard industrial material used to provide a

baseline for comparison in friction and deformation tests.

3. Mild Steel Slab Foundation: Provides the necessary structural mass

and damping. A heavy, rigid base is critical to prevent vibrations from
the motor or disc rotation from interfering with the precision of the
sensors.
4. Speed Control of DC Shunt Motor: DC shunt motors are prized for
their constant speed characteristics. The control system (likely a PWM
controller) allows you to maintain a precise sliding velocity, which is a
fundamental variable in calculating the wear rate.
5. LM Guide Way (Linear Motion): This ensures the pin or the loading
assembly moves with minimal friction and high axial accuracy. It allows
the load to be applied perpendicularly to the disc without side-loading or
binding.
6. Lubricating Pump: Facilitates the transition from "dry" wear testing
to boundary or hydrodynamic lubrication studies. It ensures a
consistent flow of lubricant to the contact interface.

Sensing & Data Acquisition

7. Load Cell & HX711 Amplifier:

8. The Load Cell converts the physical force (friction or downward
pressure) into an electrical signal.
9. The HX711 is a 24-bit analog-to-digital converter (ADC) specifically
designed to amplify the tiny millivolt signals from the load cell so the
microcontroller can read them accurately.
[Link] Plates (500g x 8): These provide the Normal Load. By
adding or removing these calibrated weights, you can precisely control
the pressure exerted at the pin-disc interface (e.g., testing at 1kg, 2kg,
etc.).

25
11.ESP32: The "brain" of the project. This powerful microcontroller
handles the data processing from the HX711, manages the motor speed
feedback, and can even log data wirelessly via Wi-Fi or Bluetooth.
[Link] Display: Provides real-time feedback of parameters such as
friction force, elapsed time, or motor RPM, allowing for immediate
monitoring without needing a serial monitor.

Power Management

[Link] Converter: Since components like the ESP32 and sensors

require low voltages (3.3V or 5V), but the motor or pump might run on
higher DC voltages, the Buck Converter efficiently steps down the
voltage while minimizing heat loss.

System Integration Summary

In operation, the DC Shunt Motor rotates the D3 Disc. The TiG5 or

SS304 Pin is held against the disc via the LM Guide Way, with the
Weighing Plates providing a known downward force. As friction occurs,
the Load Cell detects the tangential force, which is amplified by the
HX711 and processed by the ESP32 to calculate the coefficient of
friction and wear volume.

26
 Chapter-8

Fabrication work

Fabrication of Pipeline inspection Robot includes the below process

[Link]

[Link]

[Link]

[Link]

1. Cutting:

Metal plates can be cut using various methods, each suited for different
thicknesses, shapes, and levels of precision.

Common methods include laser cutting, water jet cutting, shearing, sawing
(with circular, band, or mitre saws), and specialized machines like CNC laser
cutters were used for making components for our project

2. Machining:

Metal plate machining involves shaping and cutting aluminium to create

precise components.

This is achieved through various techniques like milling, turning, and more,
all of which involve removing material to create the desired shape.
27
3. Drilling:

Drilling mild steel plate involves specific techniques to ensure clean,

accurate holes. Key factors include using appropriate drill bits, lubrication,
and proper drilling speed and pressure.

4. Welding:

welding involves joining parts using heat to create a molten pool, which
then cools and solidifies to form a weld.

While mild steel is weldable, it requires specific techniques and

considerations due to its unique properties, such as the formation of an oxide layer
and its high thermal conductivity. Common welding methods include TIG (Gas
Tungsten Arc Welding), MIG (Gas Metal Arc Welding).

28
Fabricated work:

29
 CHAPTER-9
EXPERIMENTAL SETUP

Conceptual Process:

30
Working Model

31
Testing of set up

32
 CHAPTER-10
Overview of the System

Conclusions:

Future Scope:

The project is limited in several ways and can be worked upon to broaden
its features and applications. A few of the improvements that can be implemented
are mentioned below.

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