This post is directed towards Derek (more than anyone else):
I note that you are using a carabiner manufactured by
DMM in Wales.
I presume you are aware that various models of carabiners have different profiles (cross-sectional profile).
More specifically, these days, it is getting harder to purchase a carabiner with a purely round profile (not impossible though...)
For example, the Black Diamond 'Rocklock' appears to be perfectly round (but in fact it isn't)
Link:
https://www.blackdiamondequipment.com/en_US/product/rocklock-twistlock-carabiner/ (I own a bunch of these carabiners and
I can confirm that they are definitely not perfectly round).
Most carabiners tend to be; I beam, C channel, Ovoid/Oblate, T bar, etc...
Obviously, the shape/profile of the metal stock the rope is bending around will effect your results.
Your indicated "DMM belay biner" is not drilling down to a precise model/type... and so perhaps the metal profile is not purely round?
I note you appear to favor testing in very thin, non human rated ropes (likely due to cost and availability issues?).
Thinner diameter cord that does not meet stringently defined standards could also be a factor.
Larger diameter human rated ropes that are built to exacting standards (tighter tolerances compared to para cord) - should provide better consistency.
Para cord link:
https://www.paracordplanet.com/blog/paracord-strength-sizes-and-types/ (It is unclear if you are using 'Mil-Spec' para cord?).
Even if it is Mil-Spec, it is still not the same level of stringent design/quality as per human rated rope.
I imagine that if you ran a test with thin paracord using a #206 Munter hitch, and then repeated the same test using 10.2mm EN892 dynamic rope,
the holding power of the hitch in one rope compared to the other might be different?
I just tried it with EN564 certified 6.0mm cord versus EN892 certified 11.0mm Edelrid dynamic rope... can you guess if there was a difference in brake holding power?
EDIT NOTE:I tested EN564 6.0mm Sterling accessory cord in comparison to EN892 Beal 9.1mm 'Joker'.
[ ] 6.0mm cord = 5.0kgf to hold a 20kg mass
[ ] 9.1mm rope - 4.0kgf to hold a 20kg mass
This shows that larger diameter ropes provide increased brake/holding power compared to thinner cords.
You don't have a photo of your test rig setup (the reader has to try to visualize your setup based on your description).
A clear and detailed photo - or a clear and easy to understand diagram might reveal something you overlooked...?
I'm not suggesting that your test rig was incorrectly configured... I am simply saying that humans are not infallible, and its within the realm of possibility
that you overlooked something?
EDIT NOTE:I have been using a 'Rock Exotica' Pirate carabiner.
It has a perfectly round cross-sectional profile.
Link:
https://www.rockexotica.com/pirate-auto-lock This ensures that the rope contact angle with respect to the carabiner is continuous.
Not all carabiners have a perfectly round profile - in fact, its getting harder to find such carabiners.
In my view, a perfectly round profile carabiner will help remove variability in testing...
With respect to the rope-on-rope U turn, I have found that it is not perfectly 180 degrees (ie Pi radians).
I've attached a photo with a close-up view of the 'U turn' - where it can be seen that it is not perfectly 180 degrees.
I've played around with various types of human rated ropes... and I've found that the contact angle varies according to:
[ ] the stiffness of the rope
[ ] how the rope is gripped/held by the belay person (the rope position is influenced by the belay persons grip and hand position - which appears to alter the rope-on-rope contact angle).
[ ] the test mass (higher test mass = greater compression of the #206 Crossing hitch structure)
This suggests that the test rig must be carefully setup and controlled to ensure a consistent geometric form and position of the Munter hitch).
Scaling up to heavier test mass seems to alleviate some of the variables (but in doing so adds burden to the tester who must have a way to manage the higher test mass).
Slight variations can effect the measured results...