Evaluation of the Possibility of Replacement of an SCh24 Cast Iron of Detail of a “Brake Disc” of a Car by an Aluminum-Based Dispersion-Strengthened Composition Material Prepared by Internal Oxidation

Airborne wear particle emission has been investigated in a pin-on-disc tribometer equipped with particle analysis equipment. The pins are cut out from commercial powder metallurgy automotive brake pads as with and without copper content. The discs are cut out from a commercial grey cast iron automotive brake disc as cut out and as in addition to a laser cladded with a powder mix of Ni-self fluxing alloy + 60% spheroidized fused tungsten carbide and then fine-ground. Dry sliding wear testing runs under a contact pressure of 0.6 MPa, sliding velocity of 2 m/s and a total sliding distance of 14,400 m. The test results show both wear and particle emission improvement by using laser cladded discs. The laser cladded discs in comparison to the reference grey cast iron discs do not alter pin wear substantially but achieves halved mass loss and quartered specific wear. Comparing in the same way, the friction coefficient increases from 0.5 to 0.6, and the particle number concentration decreases from over 100 to some 70 (1/cm3) and the partition of particles below 7 µm is approximately halved.

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Tribological behavior of laser textured nodular cast iron surface

Industrial Lubrication and Tribology ◽

10.1108/ilt-08-2018-0327 ◽

2019 ◽

Vol 71 (7) ◽

pp. 949-955

Author(s):

Yongmei Zhu ◽

Junjie Chen ◽

Jiajun Du ◽

Yujie Fan ◽

Jifei Zheng

Keyword(s):

Cast Iron ◽

Tribological Behavior ◽

Surface Texturing ◽

Nodular Cast Iron ◽

Area Ratio ◽

Brake System ◽

Resin Matrix ◽

Dry Sliding ◽

Brake Disc ◽

Content Type

Purpose Previous publications were mainly focused on the effect of textures under lubrication. Under dry sliding, area ratio of surface texturing (pit area ratio) and diameter of pit affect the tribological behavior. This paper aims to investigate the effect of laser surface texturing on tribological behavior of nodular cast iron under dry sliding. Design/methodology/approach Pit-like textures with different diameters and spaces were fabricated by laser on nodular cast iron (QT600-3). Using nodular cast iron (QT600-3) as the disc specimen and resin matrix composites (UCV018) as the pad specimen, the tribological test was performed with pin-on-disk reciprocating tribo-tester. Findings The coefficient of friction (COF) of the non-textured specimen was larger than that of the textured one. For the same pit diameter, a larger pit area ratio induced a slight decrease of COF, while wear volume decreased significantly. The pit diameter induced a slight decrease of COF as the pit area ratio, but its effect was weaker. Practical implications The experimental studies will help to improve the brake system such as structure modeling of brake disc. Predicting the performance and life of the brake disc in vehicle based on tribological behavior checked in test, it was proved that pit-like texture had application value in vehicle brake system. Originality/value This paper showed that the effect of pit area ratio on friction and wear was greater than that of pit diameter. The experimental results will be useful to the design on safety brake disc.

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Modelling of grey cast iron for application to brake discs for heavy vehicles

Proceedings of the Institution of Mechanical Engineers Part D Journal of Automobile Engineering ◽

10.1177/0954407016632090 ◽

2016 ◽

Vol 231 (1) ◽

pp. 35-49 ◽

Cited By ~ 4

Author(s):

Gaël Le Gigan ◽

Magnus Ekh ◽

Tore Vernersson ◽

Roger Lundén

Keyword(s):

Cast Iron ◽

Elevated Temperatures ◽

Kinematic Hardening ◽

Frictional Heating ◽

Material Model ◽

Tensile Tests ◽

Brake Disc ◽

Brake Discs ◽

Different Temperatures ◽

Tension And Compression

Cast iron brake discs are commonly used in the automotive industry, and efforts are being made to gain a better understanding of the thermal and mechanical phenomena occurring at braking. The high thermomechanical loading at braking arises from interaction between the brake disc and the brake pads. Frictional heating generates elevated temperatures with a non-uniform spatial distribution often in the form of banding or hot spotting. These phenomena contribute to material fatigue and wear and possibly also to cracking. The use of advanced calibrated material models is one important step towards a reliable analysis of the mechanical behaviour and the life of brake discs. In the present study, a material model of the Gurson–Tvergaard–Needleman type is adopted, which accounts for asymmetric yielding in tension and compression, kinematic hardening effects, viscoplastic response and temperature dependence. The material model is calibrated using specimens tested in uniaxial cyclic loading for six different temperatures ranging from room temperature to 650 °C. A special testing protocol is followed which is intended to activate the different features of the material model. Validation of the model is performed by using tensile tests and thermomechanical experiments. An application example is given where a 10° sector of a brake disc is analysed using the commercial finitie element code Abaqus under a uniformly applied heat flux on the two friction surfaces. The results indicate that the friction surface of the hat side and the neck can be critical areas with respect to fatigue for the uniform heating studied.

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EVALUATION OF THE HOMOGENEITY OF THE WORKING SURFACE OF CAST IRON BRAKE DISCS

Tribologia ◽

10.5604/01.3001.0010.8056 ◽

2017 ◽

Vol 276 (6) ◽

pp. 33-37

Author(s):

Grzegorz KINAL ◽

Marta PACZKOWSKA

Keyword(s):

Cast Iron ◽

Corrosive Wear ◽

Point Of View ◽

Brake Disc ◽

Braking Performance ◽

Brake Pads ◽

Braking System ◽

Brake Discs ◽

The One ◽

Friction Surfaces

This article deals with the one of the most important elements of modern braking systems, which is a brake disc. A brake disc is the one of more stressed parts of the braking system, and its quality and design largely determine the braking performance of the vehicle. The article describes the technology of manufacturing disc brake pads that is important from the point of view of the wear processes occurring between two friction surfaces: the brake disc and the brake pad lining. The research of the cast iron ventilated brake disc surface measured the values of the selected roughness parameters at this site. In the context of measurements, it was also determined to be able to maintain a certain value of selected geometric parameters at a given location for the group of brake discs tested of a specific type and manufactured by a particular manufacturer. The work was carried out in the aspect of the research to create a surface layer to protect the brake discs from the effects of corrosive wear.

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Residual stresses in a cast iron automotive brake disc rotor

Physica B Condensed Matter ◽

10.1016/j.physb.2006.06.112 ◽

2006 ◽

Vol 385-386 ◽

pp. 604-606 ◽

Cited By ~ 10

Author(s):

Maurice I. Ripley ◽

Oliver Kirstein

Keyword(s):

Cast Iron ◽

Residual Stresses ◽

Brake Disc ◽

Automotive Brake

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Determination of Braking Speed of Developed Hybrid Particle Reinforced Aluminium Alloy

FUOYE Journal of Engineering and Technology ◽

10.46792/fuoyejet.v6i3.670 ◽

2021 ◽

Vol 6 (3) ◽

Author(s):

Justine O Bucham ◽

Baba A Aliyu ◽

Abubakar Muhammad

Keyword(s):

Silicon Carbide ◽

Cast Iron ◽

Aluminium Alloy ◽

Nodular Cast Iron ◽

Mechanical Tests ◽

Coconut Shell ◽

Brake Disc ◽

Alloy Sample ◽

Alloy Matrix ◽

Coconut Shell Ash

Abstract- This paper is aimed at comparing the braking speed of the developed Composite Brake Disc (CBD) with that of a nodular cast iron Honda Accord (2000) Model Brake Disc (HABD). The test samples were produced from Aluminium alloy (Al6061), Coconut Shell Ash (CSA) and Silicon Carbide (SiC) by Stir casting and machined into standard specimens for microstructure analysis, density test, mechanical tests (hardness, tensile and impact), wear test and thermal test. The characterization of coconut shell ash particle was carried out using X-ray Flourescent equipment. Six samples were produced, four composite samples; C1 (70% Al, 5% SiC, 20% CSA), C2 (70% Al, 10% SiC, 15% CSA), C3 (70% Al, 15% SiC, 10% CSA) and C4 (70% Al, 20% SiC, 5% CSA), aluminium alloy sample (A1) and as-cast nodular cast iron sample (N1) obtained from HABD. Sample ‘C4’ had the best physical, mechanical, wear and thermal properties (Densty: 3.15 g/cm3, Hardness: 68 kg/mm2, Tensile Strength: 196.12 N/mm2, Impact Energy: 8.05 J, Wear rate: 0.0002328 g/m, Thermal Conductivity: 72.57 W/m-K) and was used to produce the CBD. From the values of coefficient of frictions obtained for CBD and HABD, the braking speeds were calculated and HABD was seen to have a lower braking speed (56.65 m/s) than the CBD (94.42 m/s) because of its higher coefficient of friction. The higher braking speed of the composite brake disc (CBD) as compared to the Honda Accord Brake Disc (HABD) could be as a result of inadequate reinforcements in the aluminium alloy matrix. Hence, the produced CBD cannot be used as an alternative for the nodular cast iron Honda accord brake disc (HABD) even as problems of heavy weight and breakage that may occur due to heavy impact associated with cast iron brake disc have been addressed using the developed composite.Keywords,- Aluminium Alloy, Braking Speed, Coconut Shell, Composite, Silicon Carbide

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