Development of a Systematic Diagnostic Strategy of the Repair of a Defective Universal Material Testing Machine (Model SM-100)

Abstract

The main purpose of this research is to carry out breakdown maintenance on a faulty Universal Material Testing Machine (Model SM100) that is hydraulically powered. The machine was first test run to examine its working condition and defects in its operation were noted. The components of the machine were then disassembled and their parts were inspected. The worn defective parts were corrected as appropriate and the machine parts and components were then reassembled. Test specimens were designed and machined for three different types of material and are used to test the performance of the repaired machine. Defects like nonfunctioning load indicator system, broken seals and springs, worn balls on the hydraulic pump valves, inadequate and low viscous hydraulic oil were identified in the machine. The broken seals led to the leakage of oil observed, which in turn reduces the volume of oil inside the pump and the worn balls led to the inadequate supply of oil as well as pressure generated to move the machine columns. Tensile test results on Al and mild steel specimens from the repaired machine were within the standard value. The research work has helped to repair a Universal Material Testing Machine with a little amount of money being expended on the project (monetary savings of about 80 %) and has also helped in acquiring new practical skills in maintenance engineering. The research work will provides a platform for engineers and laboratory scientists in the institutions, especially in the developing economy, to challenge themselves in maintenance of their equipments and machineries using new low-cost systematic maintenance approach.