Browse Topic: Brake components

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Hot Impulse Test for Hydraulic Brake Hose AssembliesJ1833_202510 (Current)10/13/2025
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Automotive Brake and Steering Hose Standards Comm
Test Cycle Simulation of Bench Based on Deep Reinforcement Learning15-17-03-001507/31/2024
Abstract Test cycle simulation is an essential part of the vehicle-in-the-loop test, and the deep reinforcement learning algorithm model is able to accurately control the drastic change of speed during the simulated vehicle driving process. In order to conduct a simulated cycle test of the vehicle, a vehicle model including driver, battery, motor, transmission system, and vehicle dynamics is established in MATLAB/Simulink. Additionally, a bench load simulation system based on the speed-tracking algorithm of the forward model is established. Taking the driver model action as input and the vehicle gas/brake pedal opening as the action space, the deep deterministic policy gradient (DDPG) algorithm is used to update the entire model. This process yields the dynamic response of the output end of the bench model, ultimately producing the optimal intelligent driver model to simulate the vehicle’s completion of the World Light Vehicle Test Cycle (WLTC) on the bench. The results indicate that
Gong, Xiaohao, Li, Xu, Hu, Xiong, Li, Wenli
Brake Pad Life Monitoring System using Machine learning2024-26-003201/16/2024
In vehicles, Brake Pad is an important part for controlled driving and safety. Brake Pads are made up of friction materials which wear with use. Excessive pad wear may lead to increase the brake response time and NVH issues. Currently it is not feasible for customers to check the amount of brake pad wear without the support from experienced personnel as the unit is not visible from outside. In general no feature is provided by Indian OEMs for brake pad life estimation and indication. This paper proposes a hybrid machine learning approach to predict brake pad remaining useful life. It comprises of 3 modules namely weight, temperature and wear module. Weight module is based on mathematical formulation using longitudinal vehicle dynamics to estimate the weight of the vehicle which is essentially required to calculate kinetic energy dissipated during braking. Temperature and wear module are deep neural network based machine learning modules. The technology is developed in a simplified
Iqbal, Shoaib, BHAMBRI, MIHIR, lahase, Rahul
Model Based NVH Simulator for Virtual Development2025-01-005905/05/2023
For mature virtual development, enlarging coverage of performances and driving conditions comparable with physical prototype is important. The subjective evaluation on various driving conditions to find abnormal or nonlinear phenomenon as well as objective evaluation becomes indispensable even in virtual development stage. From the previous research, the road noise had been successfully predicted and replayed from the synthesis of system models. In this study, model based NVH simulator dedicated to virtual development have been implemented. At first, in addition to road noise, motor noise was predicted from experimental models such as blocked force and transfer function of motor, mount and body according to various vehicle conditions such as speed and torque. Next, to convert driver’s inputs such as acceleration and brake pedal, mode selection button and steering wheel to vehicle condition, 1-D performance model was generated and calibrated. Finally, the audio and visual feedback
Park, Sangyoung, Dirickx, Tom, Kang, Yeon June, Nam, Jeong Min
Comparative Numerical Study on Heat Dissipation Behaviour of Conventional Disk Brake Designs for High-Performance Requirements.2022-28-042211/09/2022
The braking system of a vehicle is one of the most crucial parts for proper and safe operation. It is required to slow down and/or stop the vehicle and work by converting the kinetic energy of the wheel to heat. It is essential to dissipate the generated heat for optimal working and the long life of the disc brakes. Most of the complications and failures with a brake disc are due to problems with heat distribution and heat level absorbed by the disc. The heat is generated due to friction between the brake pad and disc. Due to overheating of brakes due to prolonged braking and heavy braking, brake fade occurs which leads to boiling of the brake fluid, gassing, and glazing of brake pads and hence reducing braking performance. Therefore, in this project, our aim is to determine the best design that allows for the most heat dissipation by analyzing four different disc brakes using computer simulations i.e CFD to study the effect on airflow and convection and FEA for thermal analysis. This
Arora, Rishabh, Rao, Vikram, Sharma, Rishab, Chahal, Rujul, Singh, Manvesh
Tutorial: Corrosion Phenomena in Brake Systems: From Basics to Future Challenges1334510/11/2022
Corrosion on braking systems is an important issue in the automotive sector. In particular, short term corrosion of the grey cast iron discs can lead to undesired corrosion attack at dealers, while long term corrosion might impair comfort and durability of the braking system. Moreover, corrosion attack of the grey cast iron might cause stiction phenomena between the breaking pad and disc leading to possible damage of the pad. Corrosion phenomena became more important for electrified power train vehicles. In this tutorial, will try to explain the basis of the electrochemical mechanism, some characterization techniques and the interaction on the stiction phenomena between the brake pad sample and the rotor (gray cast iron). Also, another aspect that will be considered is the rust removal conditions and simulations when we are considering Electric Vehicles. The goal is to give to the audience an overview from the basics of the electrochemistry to the experimental conditions test that will
Sin, Agusti
A Novel Approach for the Frequency Shift of a Single Component Eigenmode through Mass Addition in the Context of Brake Squeal Reduction15-16-01-000409/23/2022
Abstract Brake squeal reduces comfort for the vehicle occupants, damages the reputation of the respective manufacturer, and can lead to financial losses due to cost-intensive repair measures. Mode coupling is mainly held responsible for brake squeal today. Two adjacent eigenfrequencies converge and coalesce due to a changing bifurcation parameter. Several approaches have been developed to suppress brake squeal through structural changes. The main objective is to increase the distance of coupling eigenfrequencies. This work proposes a novel approach to structural modifications and sizing optimization aiming for a start at shifting a single component eigenfrequency. Locations suitable for structural changes are derived such that surrounding modes do not significantly change under the modifications. The positions of modifications are determined through a novel sensitivity calculation of the eigenmode to be shifted in frequency. In the present work, the structural changes are carried out
Deutzer, Marcel, Stender, Merten, Tüpker, Nicolas, Hoffmann, Norbert
Kinetics of Moisture Adsorption and Its Impact on Brake Pad Compression Modulus and Compressibility: Compression Modulus vs. Dynamic Modulus and Friction Variation2022-01-116509/19/2022
The kinetics of moisture adsorption is studied for copper-free brake pads. The pad weight gain is found to increase linearly with the square root of exposure time to humidity at a given temperature – the higher the humidity, the higher the weight gain. As the moisture content in the pad increases, the tangent modulus increases while the secant modulus decreases, resulting in decreasing compressibility associated with the tangent modulus of compression and increasing compressibility associated with the secant modulus of compression – compressibility defined as a reciprocal of compression modulus. Compression modulus and dynamic modulus are compared, and implications for friction coefficient variation are discussed. A rate constant of adsorption is proposed to define and compare moisture sensitivity of friction materials.
Rhee, Seong Kwan, Rathee, Aman, Singh, Shiv Raj, Sharma, Devendra
Enhancing Meta Model of the Brake Pad Friction Coefficient using the Explainable Machine Learning2022-01-117509/19/2022
As increasing system complexity and various customer demands result in the need for highly efficient vehicle development processes. Once the brake torque is predicted accurately during the driving scenario in the earlier stage, it will be able to prevent the changing the vehicle or brake system design to satisfy the legal regulation and customer requirement. As brake torque performance target allocate brake pad friction coefficient level and characteristic, the accurate friction coefficient prediction should be preceded for accurate prediction for brake torque. Generally, the friction coefficient of the brake pad is known to vary nonlinearly depending on the physical properties of the disc and the pad, as well as the rotational speed of the brake disc, the disc temperature, and the hydraulic pressure. Furthermore, it varies depending on the driving scenario even the same condition. Therefore, there was a need for a new method : machine learning to solve this problem. A Mixed Effect
Cho, Sunghyun, Bang, Sunghoon, Jang, Jiwoo, Kim, Youngjae
The Effects Of Corrosion On Particle Emissions From A Grey Cast-Iron Brake Disc2022-01-117809/19/2022
Reducing exhaust emissions has been a major focus of research for a number of years since internal combustion engines (ICE) contribute to a large number of harmful particles into the environment. As a way of reducing emissions and helping to tackle climate change, many countries are announcing that they will ban the sale of new ICE vehicles soon. Electrical vehicles (EVs) represent a popular alternative vehicle propulsion system. However, although they produce zero exhausted emissions, there is still a concern of the non-exhausted emission, such as brake dust, which can still cause harm to human health and the environment. Despite EVs primarily using regenerative braking, they still require friction brakes to supplement as and when required. Moreover, EV’s will likely continue to use the traditional grey cast iron brake rotor, which is heavy and prone to corrosion which may exacerbate the brake wear emissions. This study concentrates on emissions from a conventional grey cast iron
Ghouri, Ishmaeel, Barker, Richard, Kosarieh, Shahriar, Brooks, Peter, Barton, David
Brake Pad Wear Monitor using MOC(Motor On Caliper) EPB ECU2022-01-116709/19/2022
With the spread of new trends such as autonomous driving and vehicle subscription service, drivers may pay less attention to the maintenance of the vehicle. Brake pads being safety critical components, a wear indicator is required by the regulation. Current application of the wear indicator in the market uses whether sound generating metal strip or wire harness based pad wear sensor. The former is not effective in generating clear alarm to the driver, and the latter is now cost effective, and there is a need for more effective and low cost solution. In this paper, a pad wear monitoring system using MOC(Motor On Caliper) EPB(Electric Parking Brake) ECU is proposed. An MOC EPB is equipped with a motor, geartrain and an ECU. The motor current when applying the parking brake is influenced by the mechanical load at the brake pad side of the system. So, by analyzing the time history of the current it is possible to measure the clearance between brake pad and disc induced by the pad wear
Lee, Soohyuk
Effect of Humidity Levels on the Compressibility of Automotive Brake Friction Materials2022-01-116409/19/2022
The load-deflection relationship of automotive brake friction materials (also known as “compressibility”) is a characteristic which may both influence and advise as to brake performance, including driver experience, noise and vibration behavior, and manufacturer quality control. It has been reported that changes in environmental humidity may significantly alter friction material compressibility in a formulation-dependent fashion – effects which are important considerations for testing protocols and real-world applicability. Greening’s presentation includes a rigorous investigation of humidity-dependent properties across differing friction materials and manufacturers, taking advantage of the high resolution and excellent repeatability of the Greening Model 1140 Compressibility Test Machine. Sets of brake pads from (at least) two different manufacturers and of varied material type (non-asbestos organic, semi-metallic, low-metallic, etc.) will be weighed to assess changes to moisture
Sendler, Edward, Greening, Brent, Greening, Chuck
Re-imagining Brake Rotor Thermal Fatigue Testing to Relate to Field Use2022-01-116309/19/2022
The validation of brake rotors has remained, to this day, heavily reliant on “Thermal Abuse” or “Thermal Cracking” type testing, with many procedures so dated that most engineers active in the industry today cannot even recall the origin of the test. These procedures - of which there are many variants - all share the trait of greatly accelerating durability testing by performing repeated high power (high speed and high deceleration) brake applies to drive huge temperature gradients and internal stress, and often allowing the rotor to get very hot, to where the strength of the material from which the rotor is constructed is significantly degraded. There is little debate about whether these procedures work; by and large rotor durability issues in the field are extremely rare. However, without the connection to the duty cycle in the field, it is extremely difficult to interpret results (especially since many standards allow significant cracking before a failure is declared), and this can
Antanaitis, David, Langhardt, Jerry
Estimating Brake Pad Life in Regenerative Braking Intensive Vehicle Applications2022-01-116109/19/2022
Regenerative braking without question greatly impacts brake pad service life in the field, in most cases extending it significantly. Estimating its impact precisely has not been an overriding concern - yet – due in part to the extensive sharing of brake components between regen-intensive battery-electric and hybrid vehicles, and their more friction-brake intensive internal combustion engine powered sibling. However, a multitude of factors are elevating the need for a more accurate estimation, including the emerging of dedicated electric vehicle architectures with opportunities for optimizing the friction brake design, a sharp focus on brake particulate emissions and the role of regenerative braking, a need to make design decisions for features such as corrosion protection for brake pad and pad slide components, and the emergence of driver-facing features such as Brake Pad Life Monitoring. Tackling this question raises questions such as “is the proven braking energy and temperature
Antanaitis, David, Robere, Matthew
Design, Simulation and Topology Optimization of Rotor Disc2022-26-118805/26/2022
Brake systems are one of the most critical components of any mobile vehicle. They play a vital role in providing safety to the passengers, vehicle and surroundings. It works on basic principle of Pascals Law by applying forced frictional resistance to the rotating members of the vehicle to slow down the speed. Generally, cast iron is used as a primary material for the rotor in different applications. The current study involves the modelling of the Brake disc according to general specifications of All Terrain Vehicle and performing FEA Analysis on brake disc to study different results. The FEA analysis include the static structural to test the rigidity and ruggedness of disc, Steady and Transient Thermal Analysis to study the behavior of disc under varying thermal loads. It includes study of various parameters such as Von Mises Stress, Total Deformation, Thermal Gradient and Total Heat flux across the brake disc to evaluate the performance under extreme conditions. Different types of
Ruparelia, Rudra, Patel, Aarya, Baxi, Neel
Brake Line Repair: An Evaluation 2022-01-100103/29/2022
Brake line failures do occur, and it can happen to any vehicle. However, due to the FMVSS requirements, the brake line systems are also designed to maintain certain braking capability in the event of a brake line failure. This study was intended to further understand the effects of a brake line failure and examine the braking capability and controllability of the vehicle. A minivan was used as the test vehicle for this research. One of the brake lines of the minivan was cut and then reconnected with a compression fitting. When the compression fitting is not fully tightened, it will allow brake fluid leakage, and in the tests, the brake fluid was completely drained to simulate the empty brake fluid reservoir by repeatedly pushing the brake pedal. After the test vehicle lost all the brake fluid, braking tests were conducted. The stopping distance and the tire marks on the ground were documented. The test results show contrary to the unfounded myth that a brake line failure will result in
Arnett, Michael, Chen, H. Fred, Guenther, Dennis
Methodology and application on load monitoring using strain-gauged bolts in brake calipers2022-01-112103/29/2022
As technology evolves, the number of sensors and available data on vehicles grow exponentially. In this context, it is essential to use sensors for monitoring key components, increasing safety and reliability, and gathering data useful for mechanical dimensioning and control systems. This paper presents an application of strain-gauged bolts brake calipers fixation of two electric vehicles. With this approach it was possible to obtain the loads applied to the brake pads and correlate them with braking behavior, therefore gaining insights on braking conditions and system state. The goal of the study is analyzing the strengths and limitations of the method and proposing developments to deploy it in real applications. This topic is particularly important and novel for electric vehicles, where powertrains can create positive and negative torques and generate complex interactions with braking system. Strain-gauges are a long-known technology applied in many fields, and its usage in bolts and
de Carvalho Pinheiro, Henrique, Sisca, Lorenzo, Carello, Massimiliana, Ferraris, Alessandro, Airale, Andrea Giancarlo, Falossi, Marco, Carlevaris, Alberto
Investigation of Al2O3-Ni coated cast iron brake rotors under modified brake dynamometer test standards2022-01-030903/29/2022
Due to the reduced or less-frequent usages of the friction brakes and the lower brake rotor temperature on electrical vehicles (EV), corrosion would much likely occur on brake rotors. Using hard braking to clean the corroded rotor surfaces often leads to extra rotor surface wear. Improvement in corrosion and wear resistance is an important technological topic to brake rotors for EVs. Many original equipment manufacturers (OEM) and their suppliers are exploring surface treatments including laser cladding and thermal spray processes on cast iron rotors to combat the corrosion issues. However, mentioned surface coating processes increase the cost of brake rotors and there is a need to search for cost-effective coating processes. In this research, a new Al2O3-Ni composite coating was proposed for preparation of a commercial cast iron brake rotor using both plasma electrolytic aluminating (PEA) and electroless nickel plating (ENP) processes. The added nickel was to fit in the intrinsic
Cai, Ran, Sun, Jiayi, Zhang, Jingzeng, Tjong, Jimi, Foots, Sean, Lavelle, Mark, Nie, Xueyuan
Research on Brake Pads Particle Emissions and Temperature Reduction of a Brake Disc in Air Controlling System.2022-01-039003/29/2022
This paper addresses the brake pad particles emitted during the braking process of a vehicle in motion. The frictional-constant contact between the disc brake and brake pads generates thermal energy as a result of increased temperature within the brake disc causing wear of the brake pads. Emission of brake pad particles into the atmosphere leads to an increase in air pollution in the environment and hence becomes hazardous to the human body. In this paper, the wheel brake disc is installed in a ventilated system where the specific airflow encompassing the disc brake accounts for thermal performance and pad particle emission from the brake pads. The mathematical model of the fundamental parameters of the brake disc and ventilation is established and the behavior of heat transfer coefficient, heat generation, heat flux, temperature rise, airflow rates, brake disc cooling time, inlet and outlet speed on the ventilation system with the brake disc are carried using computational fluid
sarvar, Yovkachov, Fayzullayevich, Jamshid Valiev
Evaluating Simulation Driver Model Performance using Dynamometer Test Criteria2022-01-063803/29/2022
The influence of driver modeling and drive cycle target speed trace modification on vehicle dynamics within energy consumption simulations is studied. EPA dynamometer speed error criteria and the SAE J2951 standard are applied to simulation outputs as proposed components of simulation validation, providing guidelines for acceptable vehicle speed outputs and allowing comparison of simulation results to reported EPA dynamometer test statistics. The combined effect of driver model tuning and drive cycle interpolation methods is investigated for the UDDS, HwFET and US06 drive cycles, with EPA-specified linearly interpolated speed trace and PI controller driver as a baseline result. Additional benefits of driver tuning are presented including a reduction in unnecessarily-aggressive simulated accelerator and brake pedal actuation, resulting in a 50% or greater drop in simulated vehicle RMS jerk and peak jerk in each analyzed case compared to baseline. For the simulated vehicle, a “lazy
Legg, Thomas, Nelson, Douglas
Active brake wheel cylinder pressure control based on integrated electro-hydraulic brake system2022-01-034203/29/2022
With the development of automobile industry, the requirements of quick response, high performance are put forward for the braking system. Since the traditional braking system cannot achieve these, the international brake parts manufacturers put forward an integrated electronic braking system -the 1-Box. It can realize active braking through the servo motor. In addition, by controlling the pressure of servo cylinder and working with solenoid valves, the wheel cylinder pressure can be controlled. However, it has some problems, such as hydraulic hysteresis disturbance and complex friction obstruction, which cause obstacles to the accurate control of wheel cylinder pressure. In this paper, the active brake pressure control strategy of wheel cylinders is designed based on 1-Box. First, introduce the configuration and the working principle of wheel cylinder pressure control; Next, design the servo cylinder active brake pressure control strategy composed of servo ring and pressure ring. Servo
Zhang, Jian, Li, Linrun, Jiang, Hongwei, Liu, Qiuzheng, Wang, Yu, Yuan, Wenjian, Wu, Jian, Zhang, Xuhan
Measurement and evaluation of the conversion of thermal energy generated on the contact surface of the brake disc into electrical energy using a thermoelectric generator2022-01-021303/29/2022
The heat generated by the friction between the brake discs and the brake pad, causes the disc’s temperature to rise which affects braking performance. This generated heat flux from the contact surface of the vehicle’s brake disc does not only affect braking performance but also tend be wasted and pollute the environment. However, an accurate system is needed to make efficient use of this generated heat flux, that is usually wasted. Thermoelectric generators (TEGs) are solid-state gadgets utilized in the conversion of heat to electricity. Hence, the aim of this study is to convert the heat flux generated at the disc contact surface into electrical energy by employing a thermoelectric generator. Additionally, to store the harvested energy to power the battery which in turn charges the temperature monitoring systems. Thermoelectric generators were positioned at different geometrical points of the brake discs to achieve optimal efficiency and energy storage possibilities. A static model is
Fayzullayevich, Jamshid Valiev, Agyeman, Philip, Frimpong, Justice
DESIGN OF LOAD CELL OPERATED MAGNETIC BRAKING SYSTEM2022-01-110603/29/2022
The traditional braking system uses hydraulic fluid with components such as master cylinder, floating calliper, brake pedal, and connecting rod. The disadvantage with this system is regular maintenance, changing of oil and leakage. To overcome these disadvantages and making it cost effective this work is proposing a Load-cell operated magnetic braking system. It is reliable and requires less maintenance. The braking process involves impressing load on the load cell installed upon the steering wheel of the car. The load is converted to electric signals and will be transferred to the amplifier, then this amplified signal is supplied to hub of the rotor which is magnetic operated and applies brake. This braking system has more safety and accuracy compared to traditional braking system. Brakes are disengaged magnetically and engaged electrically. This brake system is used for dynamic stopping and holding halt and has flexibility in controlling the braking force through voltage applied
Srivastava, Jay Prakash
The Numerical Analysis of Brake Pad Related to The Properties of Composite Brake Pad Friction Material.2022-01-036503/29/2022
This project outlines the effect of changing Young’s modulus, Poisson’s ratio, and shear modulus on the natural frequencies of brake pads. It aims to improve the understanding of the influence of friction material properties on the natural frequencies and observe how the natural frequency changes with the changes in the properties of the composite brake pad friction material. In addition, two different brake pad models (Pad-A and Pad-B) were designed using CATIA V5 software to study whether different pad aspect ratios can affect the influence of friction material properties on the natural frequencies. The finite element analysis (FEA) was utilized to derive the natural frequencies and mode shapes using ABAQUS software. In addition, an experimental modal analysis (EMA) was performed on Pad-A to evaluate the accuracy of the FEA. Furthermore, the factorial analysis was applied on the obtained natural frequencies for each pad to find out the material properties that have the main effect on
Ravanbod, Mohammad
Influence of the chemical composition on the generation of cracks in brake discs2021-36-042302/10/2022
Thermoelastic instabilities in the contact of brake friction material cause hotbands and hotspots on the surface of brake disc. These phenomena generate thermal stresses that result in generation of cracks, which limit the lifetime of the discs. In the present work, the influence of the chemical composition of brake discs on the thermoelastic behavior of the system and on the lifetime of the discs was investigated. The experimental evaluation was carried out in an inertial dynamometer using the SAE J3080 standard procedure applied on a brake system. Two discs (namely A and B) with different chemical compositions were subjected to the tests. The brake pad composition was kept fixed. The thermoelastic effects on the inner surface of the disc were observed by contact (thermocouple) and noncontact measurement techniques (thermography), as well as through photographic images of the disc’s surfaces. Disc A showed negligible amount of Nb while disc B exhibited 0.360%. Besides, disc B
Flores, Roberto, Ferreira, Ney Francisco, Neiss, Patric Daniel, Barros, Liu Yesukai, Poletto, Jean Carlos, Buneder, Diogo, Lorandi, Natalia Pagnoncelli, Pavlak, Rafael Paini, Fidler, Genesis Guilherme, Lopes, Carlos Henrique Raposo
External Automatic Slack Adjuster Performance RequirementsJ1513_202111 (Current)11/03/2021
The performance requirements have been established for external automatic slack adjusters when tested to SAE J1462.
Truck and Bus Foundation Brake Committee
Driveline Parking Brake Test Procedure for Medium Duty VehiclesJ2690_202110 (Current)10/28/2021
This SAE Recommended Practice establishes uniform test procedures for friction based parking brake components used in conjunction with hydraulic service braked vehicles with a gross vehicle weight rating greater than 4500 kg (10 000 lb). The components covered in this document are the primary actuation and the foundation park brake. Various peripheral devices such as application dashboard switches or indicators are not included. These test procedures include the following: a Brake Related Tests 1 Brake Functional Performance 2 Brake Dynamic Torque Performance 3 Brake Corrosion Resistance 4 Brake Endurance with Torque 5 Brake Endurance without Torque 6 Vibration Resistance 7 Brake Ultimate Static Load 8 Brake Lining Wear Adjuster Function b Actuation Related Tests 1 Mechanical Actuator Functional Performance 2 Mechanical Actuator Endurance 3 Mechanical Actuator Quick Release 4 Mechanical Actuator Ultimate Load 5 Spring Apply Actuator Functional Performance 6 Spring Apply Actuator
Truck and Bus Hydraulic Brake Committee
Brake Lining Quality Test ProcedureJ661_202110 (Current)10/26/2021
The purpose of this SAE Recommended Practice is to establish a uniform laboratory procedure for securing and reporting the friction and wear characteristics of brake linings. The performance data obtained can be used for in-plant quality control by brake lining manufacturers and for the quality assessment of incoming shipments by the purchasers of brake linings.
Brake Linings Standards Committee
Decoding Genuine Ceramic Pad Formulations- Materials and Processing2021-01-127710/11/2021
The need to develop genuine ceramic composites for PV applications arose to overcome the challenges associated with traditional semi-metallic pads. The main focus is to achieve better performance, low noise, better pad and rotor wear, and low dust compared to semi- metallic pads. In general, brake pads convert kinetic energy to thermal energy through friction, and operating temperature in semi-metallic brake pads is higher due to the presence of steel having high thermal conductivity. Over the last decade, the customer preference has moved over to ceramic pads due to light coloured pad surface, low rotor and pad wear and low dust compared to semi-metallic pads. The traditional steel has been replaced by Aramid, engineered ceramic fibre, potassium titanate (TISMO D), lapinus fibre (RB 250) to impart similar/better performance. The current work investigates the characterisation of genuine ceramic and semi-metallic composites. Three genuine ceramic and one semi-met composite have been
Tomar, Bharat, Ali, Sharafat, Ellis, Keith, Choudhary, Yogesh
An Investigation of Property Changes of Copper-Free Brake Pads During Wear Testing: Pressure and Temperature Dependence of Pad Modulus, and the Correlation Between Modulus and Friction Coefficient2021-01-127610/11/2021
Earlier publications have demonstrated that pad and disc properties change during storage and also during the SAE J2522 Brake Effectiveness Test Procedure. The current investigation was undertaken to find out how the properties change under milder braking conditions, using the SAE J2707 Wear Test Procedure. A copper-free formulation was selected for the investigation and tested on an inertia dynamometer using a front caliper designed for a passenger car. The pad dynamic modulus changed up or down throughout the test, depending on the test conditions. The pad dynamic modulus, the pad natural frequencies and the disc natural frequencies all decreased by the end of the test. Under high-speed, high-deceleration and high-temperature braking conditions, the pad surface region permanently expands, which results in reduced dynamic modulus and also leads to reduced pad thickness loss as compared with pad weight loss. A good correlation is established between the friction coefficient and the pad
Sriwiboon, Meechai, Koetniyom, Saiprasit, Rhee, Seong Kwan, Sukultanasorn, Jittrathep, Kaewlob, Kritsana
A Molecular Dynamics Study of Tribological Properties of Silicon Carbide as a Metal-Free Friction Material2021-01-128410/11/2021
Friction materials containing metal ingredients used in the automotive industry can cause unfavorable environmental impacts. Existing laws and regulations require heavy metals in brake pads to be phased out of production. Substitutions for metals in friction materials, however, may introduce operational safety issue and other unforeseen problems. In the current study, a molecular dynamics model based on LAMMPS has been developed to study the effect of material composition, density, and geometric configurations on the tribological, mechanical, and thermal properties of silicon carbide under various contact conditions at the atomic level. Simulations which incorporate interfacial contact between surface asperities were performed to predict the elastic modulus, thermal conductivity, wear rate, and coefficient of friction. The resulting predicted properties may help enhance the performance of engineered metal-free friction materials against thermal-mechanical failures. The following
Zhang, Yizhan, LeNeave, Cortney, Yi, Yun-Bo
Thermomechanical Instabilities in Metal-Free Friction Materials Using a Nonlinear Transient Simulation Approach2021-01-128610/11/2021
The invention of metal-free friction materials is gaining popularity in the manufacturing of brake pads and clutch friction discs because of the negative factors associated with metals such as copper. To gain more insight into the failure mechanism of the recent invention during brake or clutch applications, a nonlinear transient thermomechanical model is established using Finite Element Code. The model is based on a two-dimensional configuration for an investigation on the onset of TMI (Thermo-Mechanical Instability) during sliding contact in such material. The model is validated by comparing the transient simulation results for a full-contact regime to the result from the existing eigenvalue method. A parametric study is carried out to examine how the thermal conductivities and the elastic moduli influence TMI. The simulation results show that the thermal conductivities in the transverse direction and elastic moduli in the longitudinal direction can stabilize the system. Conversely
Koranteng, Kingsford, Shaahu, Joseph-shaahu, Yi, Yun-Bo
Investigation of the Rational Area of Friction Surfaces in Contact of Friction Linings for Disc Brakes of Passenger Cars2021-01-129510/11/2021
It is important for assessing the service life of the braking mechanisms of passenger cars that are in operation is the establishment of the speed and the value of the permissible wear of the friction surfaces, which ensures the durability of the brake. The purpose of the study is to assess effect of area friction surfaces on resource of vehicle braking mechanisms. This will extend the service life of the disc brakes on cars. In the work, the regularities of wear of mating parts of disc brakes were established depending on the change in the geometric parameters of the friction surfaces and operating modes during their operation. It was found that the service life of disc brakes can be increased by 1.16 times with an increase in the area of frictional contact by 15 %, for passenger cars DAEWOO LANOS and LADA PRIORA. A comparative assessment of the wear of the new DAEWOO LANOS and LADA PRIORA brake pads, which perform cyclic emergency braking, is provided. Recommendations have been
Nazarov, Aleksandr, Krivoshapov, Sergey, Misyura, Nikolay, Belov, Valentin, Zuiev, Vladimir, Nazarov, Ivan, Sergienko, Nikolay
Sensor-controlled Friction Materials based on Liquid Friction Compounds, Chip-in-Pad Concept2021-01-129610/11/2021
In this paper, the concept of integrating thin-film piezo transducers into friction pads by using a liquid friction material compound (LIQFRIC® HP), which is capable of completely embedding the sensor surface and allowing for the force transfer due to a direct contact between sensor and friction material, is explained. The low thickness of the sensor allows for an excellent ratio of sensor volume / friction volume in the pad. The piezo transducer, besides being able to detect positive and negative pressure changes, can also be used via its EMI capability to allow measurements of changes in the shape (and therefore thickness) of the pad during and after testing. Measuring the pressure distribution, the wear and possible defect situations of the pad potentially opens up new means of friction pad- and brake operations or developments.
Milczarek, Roman Paul
Chemistry of the Brake Emissions: Influence of the Test Cycle2021-01-130010/11/2021
The reliable chemical characterization of non-exhaust emissions generated by brakes is of fundamental importance in order to provide correct information for source apportionment studies as well as for their toxicological and environmental assessment. Nowadays, the best option to obtain samples of PM10 emissions composed only by material worn from the tribological interface, i.e. the braking disc (BD) and the friction material (FM) rubbing surfaces, is to sample them on suitable collection filters at a dedicated dyno-bench, during a standard braking test cycle. In particular, the use of enclosed dyno-bench is necessary for excluding other spurious contributions from the environment, while defined test cycles are necessary to simulate standard driving conditions. Nevertheless, different braking cycles are usually characterized by different overall temperature profiles or energy parameters, which in the end have significant influence on the wear and the oxidation of the materials involved
Mancini, Alessandro, Tsyupa, Bozhena, Pin, Sonia, Bandiera, Marco, Bertasi, Federico, Federici, Matteo, Bonfanti, Andrea, Perricone, Guido, Gigli, Lara, Bolzacchini, Ezio
Investigations on the Deposition Behaviour of Brake Wear Particles on the Wheel Surface2021-01-130110/11/2021
The deposition behavior of brake wear particles on the surface of a wheel and the mechanisms on it have not been fully understood. In addition, the proportion of brake wear particles deposited on the wheel surface compared to the total emitted particles is almost unknown. This information is necessary to evaluate the number- and mass-related emission factors measured on the inertia dynamometer and to compare them with on-road and vehicle-related emission behaviour. The aim of this study is to clarify the deposition behavior of brake particles on the wheel surface. First, the real deposition behaviour is determined in on-road tests. For particle sampling, collection pads are adapted at different positions of a front and rear axle wheel. In addition to a Real Driving Emissions (RDE)-compliant test cycle, tests are performed in urban, rural and motorway sections to evaluate speed-dependent influences. Microscopic analysis is used to determine the particle number concentration and particle
Hesse, David, Hamatschek, Christopher, Feißel, Toni, Sachse, Hannes, Augsburg, Klaus, Gramstat, Sebastian
Divergence of Thickness Losses and Weight Losses of Disc Pads for Passenger Cars: High-Copper NAOs and Copper-Free Low Mets2021-01-129010/11/2021
The current investigation was undertaken to find out if lighter-weight passenger car disc pads would exhibit wear behaviors similar to pickup truck pads and commercial heavy truck drum linings in terms of the permanent volume expansion of the friction material contact surface region. 2 high-copper NonAsbestos Organic formulations and 3 copper-free LowMet formulations were tested according to the SAE J2522 test procedure. In all cases, the measured pad thickness loss was found to be less than the thickness loss calculated from the weight loss, indicating pad volume expansion in the pad surface region, in full agreement with the results from the pickup truck and heavy trucks. The heataffected swollen/expanded layer ranges from 0.27 to 0.61 mm in thickness depending on the formula and test conditions. Due to the expansion, pad durability projections made from test results based on high temperature city traffic tests can result in underestimating the actual durability. Also, one needs to
Rathee, Aman, Singh, Shiv Raj, Sharma, Devendra, Rhee, Seong Kwan
A Contribution to the Understanding of Friction and Squeal of Automotive Brakes: Wear Particle Generation and Deformation of Sliding Surface Region Influencing the Friction Coefficients of Copper-Free Disc Pads2021-01-128810/11/2021
Copper-free disc pads of 9 different compositions were made using a traditional hot molding process and tested to study frictional behavior. It is found that the friction coefficient consists primarily of two parts; one part controlled by the plastic deformation of the friction surface region of the disc and pad, and the second part controlled by the total wear of the disc and pads. As the plastic deformation and the wear are non-linear with respect to the load and sliding speed, the friction coefficient becomes a non-linear function of the load and speed. Under moderate braking conditions, the plastic deformation part is more significant in determining the friction coefficient while under more severe braking conditions, the wear contribution becomes more significant. The frictional behavior of a fade cycle is explained, and the correlation between brake squeal and disc wear is confirmed.
Rhee, Seong Kwan, Sriwiboon, Meechai, Kaewlob, Kritsana, Tiempan, Nipon
Investigation on brake disc deformation under asymmetric mechanical loads2021-01-129110/11/2021
The mechanism of automobile brake hot spots is unclear, which is a problem in the brake industry. Complex coupling between friction, heat, contact, and structural is the main difficulty in revealing the mechanism of brake hot spots. This paper proposes a new way to study the mechanism of hot spots by analyzing the deformation behavior of brake discs under asymmetric mechanical load. The actual brake is simplified into a brake disc and friction lining system, and a transient dynamic finite element model under asymmetric mechanical loads is established to analyze the deformation characteristics of brake disc. It is found that the normal deformation of the brake disc under asymmetric mechanical loads consists of two parts: low-frequency bending deformation and high-frequency waviness deformation, which are caused by the squeezing effect of the asymmetric brake pressure on the brake disc and the constraint modal vibration of the brake disc. The influence of rotation speed, the magnitude
Meng, Dejian, Tong, Yongsheng, Zhang, Lijun
Transfer Film Composition and Characteristics in Copper-Free NAO Brake Pads2021-01-127810/11/2021
Copper-free non-asbestos-organic (NAO) brake pads have been developed to satisfy the copper content regulations in North America. Copper-free NAO brake pads are required to have a stable friction coefficient owing to the electrification of the control systems, as well as to exhibit improved wear resistance to reduce brake dust emissions. Our previous study indicated that the transfer film formed on the rotor surface affects both the friction coefficient stability and amount of wear. In this study, we investigated how different types of inorganic fillers affect the transfer film formation and its composition in a wear test controlled by temperature. It was confirmed that the main component of the transfer film was iron oxide derived from the rotor. Furthermore, the contained components changed according to the appearance of the rotor surface after each wear test. When the brake pad contained potassium lithium titanate, a transfer film was formed uniformly and stably, the amount of wear
Nishimura, Keiichiro, Masuda, Katsuyuki, Yamamura, Taizo, Hara, Yasuhiro, Ono, Manabu, Sasaki, Shinya
Development of a Modeling Approach to Numerically Predict Filtration Efficiencies of Brake Dust Particle Filters2021-01-128510/11/2021
According to the European Environment Agency, air pollution is the biggest environmental health risk in Europe. Since traffic is one of the main contributors of fine dust, technical solutions are necessary to reduce the particulate emission footprint of vehicles. Also the Health Effects Institute hosted recently an international workshop on non-tailpipe emissions. Brake dust filtration concepts have proven to be a promising solution to significantly reduce fine dust emissions from brakes directly at the source. While CFD simulations for inner-ventilated brakes have become state-of-the-art, a holistic models from particle generation and emission to particle dynamics in the vicinity of the brake is not yet available. However, a good modeling approach of particle tracks is essential to predict filtration efficiencies of brake dust particle filters. It will be shown that based on current literature data and models, and independent of the turbulence model, filtration efficiencies cannot be
Keller, Florian, Krupa, Lukas, Beck, Andreas, Wörz, Tobias, Weller, Benedikt, Kohn, Kevin, Pfannkuch, Steffen, Jessberger, Thomas, Lehmann, Martin, Ashish, S
Analysis of the effect of the wedged type brake caliper piston on brake drag2021-01-129310/11/2021
Reducing brake drag has always been one of the most important goals among brake system engineers and its importance has never been higher due to the historic rise in global fuel economy and carbon emission standards. Although many studies have been done with regard to the improvement of brake drag, previous papers have focused mainly on studying the optimization of traditionally well-known factors such as geometry of the piston seal groove where the piston seal is to be located, piston materials, properties of the piston seal, and so forth. In contrast, only few papers deal with the entire mechanism of the piston roll-back. The present work tries to change the shape of the piston(wedged type) to differentiate the mechanism of the piston roll-back from the conventional method and attempts to illuminate the interaction between wedged type brake caliper piston and piston seal. Data from multi sources including several different dynamic drag tests and CAE analysis are presented and
Kim, Yooho, Kwon, Taiksang, Lee, Soonwook
Stability of hybrid composite plates with cut-out2021-28-017610/01/2021
Composites being high in strength to weight ratio is preferred for automobiles. Hybrid Composites due to its fatigue resistance, low cost and reduction in notch sensitivity makes it eligible for application in automotive industry. Hybrid composites are used in automotive anti roll-bar, brake friction material and pistons and strut bars. Carbon epoxy being costly is reinforced with glass epoxy to achieve the desired effect of weight reduction along with saving the cost. In this paper stability analysis of hybrid composite plate with elliptical cut-out is studied. Comparison between different boundary conditions that is combination of simply supported and clamped for the considered rectangular plate is being done. The effects of orientation of cut-out, stack up sequence effect, angle ply, laminate thickness effect, width of plate, changes in aspect ratio of plate as well as cut-out is being studied. Comparisons of perforated and non-perforated conditions are studied and accordingly
Gore, Renuka, Bhaskara Rao, Lokavarapu
Tribological evaluation of organic frictional composites filled with various nano- solid lubricants2021-28-025910/01/2021
Incorporation of organic fibers originate from plants in polymer composite is not new as they provide eco-friendly lighter composite and it have gained attention over a period of time because of the specific applications. The augmenting demanded by automotive sectors for wear and frictional areas where the conservation of energy is concerned is expected one with the addition of nano – solid lubricants. Our aim is to highlight the possibility of organic basalt fiber reinforced polymer composites along with three possible combination of nano – solid lubricants like graphite/graphene/ molybdenum disulfide was chosen and to fabricate tribo-materials through hot press technique. The outcome of the tribological tests (by varying load and sliding velocity) indicates that the responses of these three organic fiber based polymer composites have been effectively modified by nano-solid lubricants leading to significant enhancement as tribo materials is highlighted in higher level of load and
R, Soundararajan, Javid Firnas, Sait, Naveen raj, Nandakumar, pradeep s, sabapathy
A Comparative Study with J48 and Random Tree Classifier for Predicting the State of Hydraulic Braking System through Vibration Signals2021-28-025410/01/2021
Even though hydraulic brakes are valuable safety elements for riders, they are necessary for braking in a good condition. The state of the brake components can be determined by using vibrational signatures. In this proposed study, interactive condition monitoring with a piezo-electric transducer and the dynamic data acquisition mechanism is suggested as a potential solution to such problems using a machine learning approach. For good and poor braking conditions, the Ford EcoSport setup was used to get the vibration signal. The empirical statistical descriptive characteristics of the vibration signals were obtained and the J48 decision tree model was used in the selection. A systematic decision does not specify the sufficient number of features necessary to characterize a certain problem. Therefore, to find the right number of features a rigorous analysis is required. The failure study of the hydraulic braking system of Ford EcoSport has been determined using the decision tree
Arockia Dhanraj, Joshuva, Muthiya, S Jenoris, Subramaniam, Mohankumar, Salyan, Srikanth, Chaurasiya, Prem Kumar, Gopalan, Anitha, Anaimuthu, Shridhar
The design process for a formula student car brake disc2021-28-025210/01/2021
In today's world with fast-growing mobility, everything is becoming more compact day by day with ever-increasing technological advances. This paper deals with the design of a disc brake rotor considering the requirement of the student formula team. In this paper, different design iterations shall be realized to have maximum heat flux distribution and at the same time maintain the structural rigidity of the rotor so that it can withstand the torque requirement of an SAE vehicle especially the acceleration test. Solidworks was used for design modeling while Optistruct and Hypermesh were used to perform the CAE Analysis for the brake rotor. In this paper, we will explain various design iterations and how design can be optimized with extensive use of CAE tools by performing structural and thermal analysis, etc. The analytical results from the CAE simulation will help us to determine the slots and hole pattern on the rotor face as well as material selection for the rotor. The numerical
KUMAR, NAVNEET, Pandey, Anurag
An experimental approach to monitor the clutch thermal condition to increase the clutch life2021-28-028110/01/2021
One of the top problems that every Indian automobile manufacturer struggles to manage is the clutch early failure less than 30000 Km. This is mainly due to the extreme heating of the friction lining due to the real-world user profile in the Indian market and users inappropriate driving behaviors like Overloading the goods more than the manufacturer’s recommendation, Non recommended attachments and increased wheel size, Thick traffic leading to high level of clutch modulation and Clutch riding while running and launching the vehicle at higher gears. Although many simulation and testing are done during the development phase, above listed real world user profile and customer driving habits are inevitable by any automobile manufacturer. Hence the prime goal of this experimental research is to indicate or alert the user on the clutch thermal condition due to the driving habit and to encourage the user on right driving habits. This objective is met through an stand alone electronic system
M, Sudhan, B, Vasanthan
Comparing and analysing the static and thermal characteristics of brake disc for three different materials2021-28-025310/01/2021
In automobiles, the most commonly used braking system is disc brake. In the brake disc, rotor is the rotating part of a wheel's disc brake assembly, against which the brake pads are applied by the driver through mechanical action. So, the disk is the important component in either slowing down or stopping the vehicle. These discs were commonly made of cast iron conventionally. But the limitations with respect to cast iron are that they have less corrosion resistance and heavy in weight. In order to overcome the above-said complications, alternate materials for disc have to be found. The main objective of this paper is to analyze the characteristics of three different materials and compare their results and suggest a suitable material that highly influences the conventional material and has better performance under on-road rigorous braking conditions. In order to find an alternative material for Cast Iron (CI), EN31, Ti-6Al-4V(Ti alloy) acts as a potential candidate in offering great
K, Kaviyarasan, R, Soundararajan, Richter R, Abhisheak, K, Siva, Purusothaman, S, S, Shiva Gurunathan
Effect of various synthetic and natural fibers for the production of copper-free automotive brake pads2021-28-027410/01/2021
In recent years, asbestos and copper free brake pads have attracted researchers due to its adverse environmental risks which make it mandatory for the manufacturers to look for a reliable replacement. It is essential to identify new combination of synthetic and natural fibers for the potential automotive brake pads. Experiments were planned to produce various frictional composites (1) glass fiber (2) carbon fiber (3) basalt fiber (4) hemp fiber with standard additional materials through hot pressing technique. The developed form of brake pads were tested as per ASTM and industrial standard practices like hardness, wear and friction. Also worn surface analysis was performed using a scanning electron microscope. Most noteworthy tribometric operating parameters like load (10-40N), sliding velocity (1-5m/s) were being considered and wear mechanism for various types of composites and their performances are being discussed. In order to prove the application suitability, recovering synthetic
R, Soundararajan, Soundarrajan, Karthik, Rengaraj, Jeyakumar, gopal, Shanthosh
INTEGRATED ACTIVE SAFETY SYSTEM FOR MOTOR GRADERS2021-26-013709/22/2021
Safety of the operators in any equipment can be achieved by both passive and active systems. Passive safety system includes Seat belt, primary air bag, bumper, and other structural components which protects the operator from injuries during accidents. On the other side, Active safety systems like Braking, Steering, Collision avoidance system, operator fatigue monitoring systems minimise and eliminates the accidents among which the Brake system is primarily used to control and stop the equipment. Motor graders are work equipment which are designed to carry out many works like grading, spreading, levelling, metal mixing in road construction and many other infrastructure projects. Considering the field operating conditions of motor grader, it is very essential to provide excellent brake system to control and stop the equipment. In order to obtain maximum productivity the equipment speed is kept substantially high. Brake systems are operated using Air, Hydraulics, etc., among which the Air
KUMARAN, RAJASEKAR, hs, satish chandra
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