Improving the Surface Characteristics by Employing FSP on the Composites for the Automobile Brake Pad Application

2019 ◽  
Author(s):  
P. Ashwath ◽  
M. Anthony Xavior ◽  
R. Rajendran
Keyword(s):  
Surface Characterization ◽  
Research Work ◽  
Hot Extrusion ◽  
Surface Characteristics ◽  
Extrusion Process ◽  
Wear Loss ◽  
Brake Disc ◽  
Brake Pad ◽  
Brake Pads ◽  
Friction Stir

Abstract Looking at the background of the recent research on the area of the brake friction materials, composites are gaining the trust in being a potential replacement among the automobile sectors. The fabrication of the AA 2024 composites reinforced with 3 wt % Al2O3 is done using powder metallurgy technique followed by hot extrusion process. Current research work focuses on friction stir processed surface modified composites evaluated for the replacement of the currently used brake pads materials in automobile sectors. Surface characterization is carried out on the worn-out tracks of both brake materials developed and the counterpart employed using scanning electron microscope and XRD. The counterpart used in pin on disc configuration is exactly the material used in the automobile application (i.e. automobile brake disc plate material). Impact characteristics and tensile studies after friction stir processing (FSP) is studied as well. Coefficient of friction and wear loss characteristics in aspect of the tribological life of the composites developed is compared with the existing automobile brake pad components and found that FSP on composites served the purpose of the materials used in existing brake pads material.

scholarly journals Friction-Induced Recycling Process for User-Specific Semi-Finished Product Production

Metals ◽  
2021 ◽  
Vol 11 (4) ◽  
pp. 663
Author(s):  
Thomas Borgert ◽  
Werner Homberg
Keyword(s):  
High Efficiency ◽  
Research Work ◽  
Hot Extrusion ◽  
Extrusion Process ◽  
Efficient Production ◽  
Secondary Aluminum ◽  
Shape Accuracy ◽  
Aluminum Chips ◽  
Spinning Process ◽  
Complex Parts

Modern forming processes often allow today the efficient production of complex parts. In order to increase the sustainability of forming processes it would be favorable if the forming of workpieces becomes possible using production waste. At the Chair of Forming and Machining Technology of the Paderborn University (LUF) research is presently conducted with the overall goal to produce workpieces directly from secondary aluminum (e.g., powder and chips). Therefore, friction-based forming processes like friction spinning (or cognate processes) are used due to their high efficiency. As a pre-step, the production of semi-finished parts was the subject of accorded research work at the LUF. Therefore, a friction-based hot extrusion process was used for the full recycling or rework of aluminum chips into profiles. Investigations of the recycled semi-finished products show that they are comparable to conventionally produced semi-finished products in terms of dimensional stability and shape accuracy. An analysis of the mechanical properties of hardness and tensile strength shows that a final product with good and homogeneously distributed properties can be produced. Furthermore, significant correlations to the friction spinning process could be found that are useful for the above-mentioned direct part production from secondary aluminum.

Brake Wear Particle Size and Shape Analysis of Non-Asbestos Organic (NAO) and Semi Metallic Brake Pad

2014 ◽  
Vol 71 (2) ◽  
Author(s):  
Hussain, S. ◽  
M.K Abdul Hamid ◽  
A.R Mat Lazim ◽  
A.R. Abu Bakar
Keyword(s):  
Particle Size ◽  
Wear Particle ◽  
Brake Disc ◽  
Wear Particles ◽  
Brake Pad ◽  
Brake Pads ◽  
Size And Shape ◽  
Brake Wear Particles ◽  
Brake Wear ◽  
Particle Size And Shape

Brake wear particles resulting from friction between the brake pad and disc are common in brake system. In this work brake wear particles were analyzed based on the size and shape to investigate the effects of speed and load applied to the generation of brake wear particles. Scanning electron microscopy (SEM) with energy-dispersive X-ray spectroscopy (EDX) was used to identify the size, shape and element compositions of these particles. Two types of brake pads were studied which are non-asbestos organic and semi metallic brake pads. Results showed that the size and shape of the particles generatedvary significantly depending on the applied brake load, and less significantly on brake disc speed. The wear particle becomes bigger with increasing applied brake pressure. The wear particle size varies from 300 nm to 600 µm, and contained elements such as carbon, oxygen, magnesium, aluminum, sulfur and iron.

THE NEW INERTIA DYNAMOMETER FOR FRICTION AND WEAR TESTING OF BRAKE PADS AND BRAKE DISCS

Tribologia ◽  
2019 ◽  
Vol 286 (4) ◽  
pp. 113-119
Author(s):  
Waldemar TUSZYŃSKI ◽  
Michał GIBAŁA ◽  
Andrzej GOSPODARCZYK ◽  
Stanisław KOZIOŁ ◽  
Krzysztof MATECKI ◽  
...  
Keyword(s):  
Tribological Properties ◽  
Friction And Wear ◽  
Wear Testing ◽  
Driving Safety ◽  
Brake Disc ◽  
Brake Pad ◽  
Vehicle Class ◽  
Brake Pads ◽  
Test Methodology ◽  
Brake Discs

For the sake of driving safety, the right choice of the brake pad friction material and its manufacturing processes to obtain the appropriate tribological properties is a matter of priority for brake pad manufacturers. Determination of the tribological properties is best done in component tests, i.e. in the setup: brake pads – brake disc. At the request of one of the domestic brake pad manufacturers, as part of the POIR project, an inertia dynamometer for testing friction and wear of brake pads and brake discs was developed and manufactured, which was given the symbol T-33. A test methodology was developed based on the “Cold application section” procedure described in SAE J2522:2003. The T-33 inertia dynamometer is designed for testing brake pads and brake discs intended for five vehicles representing the passenger vehicle class and vans. The paper presents the new test stand, test methodology, and results of verification tests of the T-33 dynamometer (interlaboratory comparison tests) performed on the Cinquecento vehicle brake setup.

scholarly journals Impact of Brake Pad Structure on Temperature and Stress Fields of Brake Disc

2013 ◽  
Vol 2013 ◽  
pp. 1-9 ◽  
Author(s):  
Guoshun Wang ◽  
Rong Fu
Keyword(s):  
Structure Factor ◽  
Friction Pair ◽  
Flow Distribution ◽  
Peak Temperature ◽  
Brake Disc ◽  
Brake Pad ◽  
Brake Pads ◽  
Finite Element Software ◽  
Circular Structure ◽  
Friction Energy

Utilizing ABAQUS finite element software, the study established the relationship between a brake pad structure and distributions of temperature and thermal stress on brake disc. By introducing radial structure factor and circular structure factor concepts, the research characterized the effect of friction block radial and circumferential arrangement on temperature field of the brake disc. A method was proposed for improving heat flow distribution of the brake disc through optimizing the position of the friction block of the brake pad. Structure optimization was conducted on brake pads composed of 5 or 7 circular friction blocks. The result shows that, with the same overall contact area of friction pair, an appropriate brake pad structure can make the friction energy distribute evenly and therefore lowers peak temperature and stress of the brake disc. Compared with a brake pad of 7 friction blocks, an optimized brake pad of 5 friction blocks lowered the peak temperature of the corresponding brake disc by 4.9% and reduced the highest stress by 10.7%.

scholarly journals Experimental Evaluation of Brake Pad Material Propensity to Stick-Slip and Groan Noise Emission

Lubricants ◽  
2018 ◽  
Vol 6 (4) ◽  
pp. 107 ◽  
Author(s):  
Alessandro Lazzari ◽  
Davide Tonazzi ◽  
Giovanni Conidi ◽  
Cristian Malmassari ◽  
Andrea Cerutti ◽  
...  
Keyword(s):  
Low Frequency ◽  
Dynamic Responses ◽  
Brake Disc ◽  
Frequency Noise ◽  
Brake Pad ◽  
Noise Emission ◽  
Stick Slip ◽  
Brake Pads ◽  
Noise Vibration ◽  
Worn Surface

Frictional and dynamic responses of brake pad materials, when sliding on brake disc counterfaces, are at the origin of noise, vibration and harshness (NVH) issues such as brake noise emissions. In more detail, groan is a low frequency noise emission often associated to the stick-slip frictional response of the brake system. The instability of such contact is the result of the coupling between the system dynamics and the frictional response of the materials in contact. In this work, an experimental approach is proposed for measuring the frictional response and the propensity to generate stick-slip of different lining materials, coming from commercial brake pads, when sliding on a worn surface of a brake disc, under the same controlled boundary conditions. The proposed methodology allowed for comparing the propensity of the tested pad materials to stick-slip vibrations, which is in agreement with feedback from automotive industry on groan emission.

scholarly journals Bicycle Disc Brake Thermal Performance: Combining Dynamometer Tests, Bicycle Experiments, and Modeling

Proceedings ◽  
2020 ◽  
Vol 49 (1) ◽  
pp. 100
Author(s):  
Ioan Feier ◽  
Joseph Way ◽  
Rob Redfield
Keyword(s):  
Thermal Model ◽  
Normal Force ◽  
Field Trials ◽  
Brake Disc ◽  
Disc Brake ◽  
Brake Pad ◽  
Brake Pads ◽  
Disc Brakes ◽  
Friction Curve ◽  
Friction Performance

High-power bicycle disc braking can create excessive temperatures and boiling brake fluid, resulting in performance degradation and damage. The goal of this work is to understand brake friction performance and thermal behavior for bicycle disc brakes. A previously described disc braking dynamometer is used to assess brake pad performance of sintered metallic brake pads, organic brake pads, and ‘power’ organic pads in up to 400 W of braking power. The friction coefficient is found to be dependent on both temperature and normal force. Friction curve fits are provided for temperatures between 300 K and 550 K. Organic and ‘power’ organic pads are found to have similar behavior, and have higher friction coefficients compared to metallic pads. Further, brakes on an instrumented bicycle are tested in outdoor field trials during downhill descent. A MATLAB thermal model successfully predicts the downhill field brake disc temperatures when using the friction data curve fits.

The effect of reduced contact area on the occurrence of disc brake squeals for an automotive brake pad

2000 ◽  
Vol 214 (5) ◽  
pp. 561-568 ◽  
Author(s):  
F Bergman ◽  
M Eriksson ◽  
S Jacobson
Keyword(s):  
Contact Area ◽  
Friction Material ◽  
Contact Length ◽  
Brake Disc ◽  
Brake Pad ◽  
Surface Geometry ◽  
Brake Pads ◽  
Trailing Edges ◽  
Squeal Noise ◽  
Automotive Brake

Three sets of brake pads were subjected to a series of squeal tests. The pad area in contact with the brake disc was successively reduced down to 50 per cent of the original by removal of friction material either at the leading and trailing edges, at the outer and inner edges or spotwise removal of interior area by drilling. The pad surface geometry strongly affected the occurrence of brake squeals, with a significant reduction for all three pads with 50 per cent contact area. However, the average squeal noise level seems to be controlled by the pad contact length in the sliding direction.

Microstructural and Mechanical Behaviour Evaluation of Mg-Al-Zn Alloy Friction Stir Welded Joint

2020 ◽  
Vol 17 (3) ◽  
pp. 8150-8159
Author(s):  
Kulwant Singh ◽  
Gurbhinder Singh ◽  
Harmeet Singh
Keyword(s):  
Heat Treatment ◽  
Friction Stir Welding ◽  
Magnesium Alloys ◽  
Mechanical Performance ◽  
Fuel Efficiency ◽  
Research Work ◽  
Grain Structure ◽  
Tensile Fracture ◽  
Friction Stir ◽  
The Impact

The weight reduction concept is most effective to reduce the emissions of greenhouse gases from vehicles, which also improves fuel efficiency. Amongst lightweight materials, magnesium alloys are attractive to the automotive sector as a structural material. Welding feasibility of magnesium alloys acts as an influential role in its usage for lightweight prospects. Friction stir welding (FSW) is an appropriate technique as compared to other welding techniques to join magnesium alloys. Field of friction stir welding is emerging in the current scenario. The friction stir welding technique has been selected to weld AZ91 magnesium alloys in the current research work. The microstructure and mechanical characteristics of the produced FSW butt joints have been investigated. Further, the influence of post welding heat treatment (at 260 °C for 1 h) on these properties has also been examined. Post welding heat treatment (PWHT) resulted in the improvement of the grain structure of weld zones which affected the mechanical performance of the joints. After heat treatment, the tensile strength and elongation of the joint increased by 12.6 % and 31.9 % respectively. It is proven that after PWHT, the microhardness of the stir zone reduced and a comparatively smoothened microhardness profile of the FSW joint obtained. No considerable variation in the location of the tensile fracture was witnessed after PWHT. The results show that the impact toughness of the weld joints further decreases after post welding heat treatment.

Production of Asbestos-free Brake Pad Using Groundnut Shell as Filler Material

2018 ◽  
Vol 4 (12) ◽  
Author(s):  
W. C. Solomon ◽  
M. T. Lilly ◽  
J. I. Sodiki
Keyword(s):  
Phenolic Resin ◽  
Cost Effective ◽  
Filler Material ◽  
Particle Sizes ◽  
Brake Pad ◽  
Brake Pads ◽  
Environmental Friendly ◽  
Sieve Size ◽  
Groundnut Shell ◽  
The Cost

The development and evaluation of brake pads using groundnut shell (GS) particles as substitute material for asbestos were carried out in this study. This was with a view to harnessing the properties of GS, which is largely deposited as waste, and in replacing asbestos which is carcinogenic in nature despite its good tribological and mechanical properties. Two sets of composite material were developed using varying particle sizes of GS as filler material, with phenolic resin as binder with percentage compositions of 45% and 50% respectively. Results obtained indicate that the compressive strength and density increase as the sieve size of the filler material decreases, while water and oil absorption rates increase with an increase in sieve size of GS particle. This study also indicates that the cost of producing brake pad can be reduced by 19.14 percent if GS is use as filler material in producing brake pad. The results when compared with those of asbestos and industrial waste showed that GS particle can be used as an effective replacement for asbestos in producing automobile brake pad. Unlike asbestos, GS-based brake pads are environmental friendly, biodegradable and cost effective.

Tribological and dynamical analysis of a brake pad with multiple blocks for a high-speed train

2019 ◽  
Vol 234 (11) ◽  
pp. 1771-1788
Author(s):  
YK Wu ◽  
JL Mo ◽  
B Tang ◽  
JW Xu ◽  
B Huang ◽  
...  
Keyword(s):  
High Speed ◽  
Wear Behavior ◽  
Dynamical Analysis ◽  
Brake Disc ◽  
Brake Pad ◽  
High Speed Train ◽  
Brake Squeal ◽  
Element Analysis ◽  
Single Block ◽  
Middle Ring

In this research, the tribological and dynamical characteristics of a brake pad with multiple blocks are investigated using experimental and numerical methods. A dynamometer with a multiblock brake pad configuration on a brake disc is developed and a series of drag-type tests are conducted to study the brake squeal and wear behavior of a high-speed train brake system. Finite element analysis is performed to derive physical explanations for the observed experimental phenomena. The experimental and numerical results show that the rotational speed and braking force have important influences on the brake squeal; the trends of the multiblock and single-block systems are different. In the multiblock brake pad, the different blocks exhibit significantly different magnitudes of contact stresses and vibration accelerations. The blocks located in the inner and outer rings have higher vibration acceleration amplitudes and stronger vibration energies than the blocks located in the middle ring.

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