Wear debris monitoring and analysis is a common practice for the condition assessment of engine and transmission health. Oil debris monitoring (ODM) and electronic chip detectors (ECD) are two common methods deployed for continuous monitoring of oil wetted component health in-flight. This study evaluates the diagnostic performance of the two sensing technologies within controlled rolling element bearing (REB) fault experiments. Progressive visual inspection of the REB spall progression through failure provided a ground truth against which both systems could be compared. Quantifiable metrics of reliability, diagnostic accuracy, provided maintenance interval were defined to create a framework for condition-based maintenance (CBM) program decision making. In summary, it was found that the ODM sensor system provided earlier fault notice, but more so, vastly outperformed the ECD in reliability and avoidance of false positives.

Mahmoud, Hassan, Rodger, Steve, Oszmian, Adam

Schey’s Tribology in Metalworking: Friction, Lubrication, and Wear

B-ASM-0572/28/2024

Schey’s Tribology in Metalworking—Friction, Lubrication, and Wear is an update to the seminal text Tribology in Metalworking by John Schey, originally published by ASM International in 1983. The 1983 first edition served as a recognized essential resource for researchers in the fields of manufacturing tribology and metal forming for many decades. This 2023 update preserves the essential information in that first edition but provides a thorough update, including a description of the significant advances in tribological research and detailed information for every metal forming process.

A Predictive Approach to Estimate Tyre Wear Characteristics

2024-26-03131/16/2024

Tyre wear is a significant concern for the automotive industry due to multiple reasons that include vehicle performance, safety, economy, environmental (particulate matter emission) aspects, etc. Therefore, ensuring higher tyre tread wear resistance is one of the most important criteria while developing a new tyre. Tyre wear phenomenon is influenced by various factors, such as, road conditions, driving habits, maintenance practices and tyre design parameters (construction, geometry and material). The wear assessment through classical field-testing approach consumes significant time and resources. Therefore, digital predictive tools are very useful in predicting wear characteristics at the early stage of tyre development process. In this study, an attempt has been made to capture the impact of tread geometry, tread material, vehicle geometry, vehicle speed, test track geometry, etc. on tyre wear. A commercial finite element code, Abaqus was utilized for tyre structural simulation and

Bedi, Vinay Kumar, Rana, Kashif, Mahata, Pundarik, Ghosh, Prasenjit, Mukhopadhyay, Rabindra

EPS calibration in multiple modes including terrain mode for SUV to achieve precision steering feel and Handling enhancement.

2024-26-00551/16/2024

In automobiles, the SUV category of cars encounters almost all types of terrain, including Sand, Mud, Snow, Gravel, etc. Despite changes in terrain, today's customers want no deterioration in Ride, Handling, or steering performance feel, which poses challenges for automakers while calibrating the performance attributes of the vehicle. This technical paper would be focusing on extracting optimum steering performance over any terrain by providing versatile terrain specific EPAS logics through dedicated steering modes linked to the Terrain modes in addition to the Drive modes. Comfort, Normal & Sports are the usual Drive modes, wherein Comfort would have the maximum assist, Normal would have the optimum assist, and Sport would have a higher damping and weighted feel. Similarly, after a lot of subjective evaluations over different Terrains in India, suitable EPAS calibration modes are adapted. A BLAC motor has been selected for its precise control over assist torque and wider scope for

Gaikwad, Vivek, Shah, Samarth, Krishnan, Nandhakumar, K, Rajakumar

Reliability prediction and demonstration for wear failure mechanism

2024-26-03231/16/2024

This paper presents a methodology of integrating wear models in a system level model to assess the risk of failure in a field application, through endurance testing at the system level. Correlation of the wear prediction by the system-integrated wear model with actual measurement was performed and used to estimate the field operation reliability. Results are shown for sliding wear as well as impact wear phenomenon in this paper. The methodology adopted is to develop a system level dynamic model of its operation to capture the forces at the wear interfaces which is then integrated with Archard’s wear model. This model is then run using the system level sensor data captured during endurance testing to replicate the wear interface dynamics and predict the wear phenomenon. Since this wear cannot be measured during system operation, the effect of wear which results in a system level performance change is also modelled. This enables to track the actual system level performance change during

sr, Ranjith Kumar, Soma, Nagaraju

Investigation of Synchronizer Ring Failure in a Commercial Vehicle Transmission

2024-26-03831/16/2024

The commercial vehicles market is dominated with manual transmission, due to less ownership cost. Generally, the commercial vehicles are used in large numbers by the fleet owners. The transmission endurance life is very important to a vehicle owner. On the other hand, the driver fatigue can be reduced with smooth change process. The gear change process in a manual transmission is carried out with the help of the synchronizer pack. The crucial function of synchronizer pack in an automotive transmission is to match the speed of the target gear for smooth gear shifting. In a transmission the loose and the weakest part is the synchronizer ring. The failure of synchronizer affects smooth gear shifting and it also affects the endurance life of the transmission. The synchronizer ring can fail due to poor structural strength, synchronizer liner wear, synchronizer liner burning etc. The synchronizer liner burning is very difficult to analyze since the liner wear pattern are very uneven and the

Jamadade, Gajanan, K, Barathi Raja, Chatterjee, Soumik

Data-Driven Toe Misalignment Detection in Single-Unit Twin-Axle Trucks

2024-26-02781/16/2024

Toe misalignment detection and its correction are important periodic tasks recommended by Original Equipment Manufacturers (OEMs) for Heavy Commercial Road Vehicles (HCRVs) to prevent premature tyre wear and improve fuel economy. Existing misalignment detection methods need skilled professionals to operate sophisticated equipment, while automated methods require additional sensors, which are not readily available in most trucks, making their implementation challenging. This study explores the effectiveness of a data-driven method to detect toe misalignment in single-unit twin-axle trucks with symmetric and asymmetric toe configurations. This method involves continuous monitoring of lateral dynamics variables measurable using sensors present in most trucks making it practically tractable. Ramp steer manoeuvres with a 45◦ steering angle and a rise time of 3 seconds in two directions (clockwise and anticlockwise) for two toe configurations (symmetric and asymmetric) constituted the four

Burande, Kalyani, Grandhe, Roshan, Mukhopadhyay, Arko, Sharma, Mitanshu, Shankar Ram, C S

A computational approach to Fretting Wear prediction of Steel Gaskets under Thermo-Mechanical load using Archards wear model

2024-26-02731/16/2024

IC Engine is the heart of an automobile. The failure in any component of the engine will directly affect the performance of the vehicle. The gaskets are among the many vital parts of an IC engine that are essential in ensuring appropriate sealing to prevent gas and liquid leakage and maintain optimal engine efficiency. Engines use a variety of gasket types to accommodate various sealing requirements. Among them the exhaust manifold gaskets is one of the critical gasket elements in IC engines which seals between Cylinder head and extremely hot Exhaust Manifold, this prevents the leakage of hot exhaust gasses produced during combustion. The gaskets are crucial components because they endure extremely high mechanical loads from the exhaust manifold sliding and banana-shaped bending brought on by thermal expansion, as well as extremely high thermal loads from the high exhaust gas temperatures, which are around 1000°C. These gaskets are additionally subjected to extremely high bolt loads

Reddy, Rajavardhan, Kulkarni, Sanjeev, R B, Govind, Mueller, Frank Oliver

Desensorization: A Novel Method for Urea Concentration Deterioration Detection in BSVI Engines

2024-26-01541/16/2024

Urea concentration deterioration detection in BSVI engines is vital for maintaining compliance with emission regulations. This paper introduces a groundbreaking desensorization method, which offers numerous benefits in detecting urea concentration deterioration by estimating the drop in catalyst conversion efficiency. Traditionally, urea quality sensors have been employed to measure the absolute concentration of urea in the aqueous solution (Diesel Exhaust Fluid – DEF). This information is used to detect usage of poor quality DEF. However, desensorization eliminates the need for dedicated sensors, reducing complexity, cost, and potential sensor-related errors. The proposed method leverages the strong relationship between catalyst conversion efficiency and urea concentration. By monitoring catalyst inlet and outlet NOx values using NOx sensors, the efficiency of the catalyst can be estimated. This estimation allows for the detection of urea concentration deterioration, ensuring that NOx

Venkat, Harish, Kumar, Gokul Elumalai, Kumar, Kosalaraman, G, Vijayakumar

Retain Newness of Commercial vehicle: Lining and Paneling

2024-26-01881/16/2024

Commercial vehicle are exposed to harsh environment conditions like dust, mud, wind, rain, extreme sun and winter throughout. Apart from white goods and other conventional loading these vehicles also used in applications which involve Handling of Dirty Loads, Construction Raw materials, Mining Industry etc. which leads to fast deterioration of Interiors. Also, in most cases drivers are not the owners. Hence due to high cost of Cleaning at dealerships and low Product maintenance awareness amongst Commercial Vehicle Users, on Road Washing & Cleaning by riverside is common practice which leads to early deterioration of Interior trims. This paper deals with the retention of newness of soft trim parts such as headliner and wall trims. Causes of product deterioration and attributes which influence newness like product appeal, NVH, perceived quality, environmental impact, geometry retention over time etc. have been discussed in detail. Material properties and design considerations for

Shah, Kapil, Apte, Sanjay, Navsariwala, Prashant, Kumar, Sunil, Komar, Sanju, ghodageri, santosh, SURENDRAN, SHIJU

Influence of Rotorcraft Gearbox Lubricants on the Relative Adhesive Wear of Rolling Element Bearing Material Pairs

F-0079-2023-18144

5/16/2023

Jr., Carl, Sadinski, Robert, Hullenbaugh, Gretchen

Tutorial: Building the Bridge Testing Measurement and Tribology

1335210/12/2022

Different ingredients of the friction material have different effects on its tribological behavior, some of them conflicting and interfering among themselves (abrasives can increase performance, but also reduce lining life and cause overheating�). This tutorial will try to explain some of the features of dyno/vehicle tests that can be affected by friction materials, and what on the contrary is typically out of the scope of its characterization, and more pertinent to caliper, rotor or system functionalities. The goal is to give the audience an overview of how �chemists�, compounders, look at brake testing, and what they can learn when working on new developments. Outline: � Introduction (classes of raw materials, with their main effect & drawbacks to determine the main tribological effects: Friction level, wear, noise, thermals�) � A formulation approach to Design. Overview of design considerations based on the most relevant tests: how are formulators looking at these tests, to define

Schandelmeier, Brandie

Relative Adhesive Wear Performance of Rolling Element Bearings Material Pairs

F-0078-2022-17602

5/10/2022

ABSTRACT

Sadinski, Robert, Hager(Jr.), Carl, Prock, Dave

Wear and Friction of PTFE and PEEK Coated Cast Iron Piston Ring

2022-01-03803/29/2022

In engine 30% of the total energy is lost due to the friction between piston ring and cylinder liner due to their constant rubbing motion. A piston that reciprocates at high speeds has piston rings that constantly scrape against the wall leading to high frictional losses within the engine. The engine has to work against this resistance to provide the required power, and hence it will consume more fuel. For this reason, material used for these components is more crucial. Reduction of surface friction between moving parts in order to increase overall efficiency can be achieved by suitable coating. The most commonly used piston rings are coated with chromium layers that are electroplated which is being replaced by chrome plating. Low coefficient of friction (COF) and high wear resistance can be achieved by self-lubricating coating of PTFE and PEEK polymer-based composite coatings. Experimental results showed that the PEEK and PTFE coating performed better in terms of friction and wear

Rajendran, R.

A Molecular Dynamics Study of Tribological Properties of Silicon Carbide as a Metal-Free Friction Material

2021-01-128410/11/2021

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

Investigation of the Rational Area of Friction Surfaces in Contact of Friction Linings for Disc Brakes of Passenger Cars

2021-01-129510/11/2021

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

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 Coefficient

2021-01-127610/11/2021

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

Measurement of Particle Dynamics on the Real Vehicle in Different Driving Scenarios with Swarm Sensors

2021-01-129910/11/2021

Due to the increase in public attention in the analysis of non-exhaust emission sources because of the growing electrification of vehicles, measurements have been performed in recent years to develop a consistent test standard. In particular, the consideration of tyre and brake abrasion took a predominant position due to the small particle sizes. With measurements under controlled and laboratory-like athmosphere, for example for brakes on dynamometers, attempts have been made to create a uniform test standard according to the Worldwide harmonized Light vehicles Test Procedure (WLTP). However, a transfer to the real driving environment is not yet feasible because of many external disturbance variables, such as the wheel housing or atmospheric variables. Typical reference measurement sensors in the vehicle are only suitable to a limited extent for mobile operation due to their size and the necessary measurement infrastructure. The aim of this work is to analyse swarm measurements on a

Ostermeyer, Georg-Peter, Lehne-Wandrey, Guido, Sandgaard, Malte

Investigations on the Deposition Behaviour of Brake Wear Particles on the Wheel Surface

2021-01-130110/11/2021

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

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 Pads

2021-01-128810/11/2021

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

Chemistry of the Brake Emissions: Influence of the Test Cycle

2021-01-130010/11/2021

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

Divergence of Thickness Losses and Weight Losses of Disc Pads for Passenger Cars: High-Copper NAOs and Copper-Free Low Mets

2021-01-129010/11/2021

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

Front Axle Kingpin Bush - Evaluation of Wear Rate in Operating Conditions

2021-26-04739/22/2021

In automobiles, front axle assembly is a main load bearing member and houses steering linkages. Front axle assembly has two main parts viz. axle beam and axle arm, interconnected by a kingpin. This kingpin allows the rotation of axle arm during steering events. To avoid metal to metal contact between axle arm and kingpin, bushes are housed on the top and bottom half of the axle arm & in axle beam. Due to radial load and steering rotation, as a weak member, bushes will wear out faster. This affects the proper functioning of steering mechanism. Hence, the bushes need to be evaluated prior to its implementation in vehicle. In general, bushes are evaluated using Pin-On-Disc test as a comparative study, but it does not simulate exact boundary conditions as in vehicle. Next option is vehicle level validation but leads to more lead time and testing cost. Hence, as an optimized solution, the same vehicle operating conditions can be replicated in component level testing. Considering the

Bakthavachalam, Sathish Kumar, N, Gopi Kannan, Narasimman, Obuli Karthikeyan, R, Suresh

Bogie Wear Pad - A comparative study

2021-26-04429/22/2021

Bogie-type suspensions for trucks are comprised of two axles and a central spring pack on each side of the truck chassis. Bogie suspensions have a good load distribution between the axles and are used for severe applications in trucks, in off-road conditions thereby subjecting them to extreme stain and load. In today’s competitive market scenario, it of utmost importance to minimize down time in commercial vehicles as it directly corresponds to loss in business which leads to customer dissatisfaction. It is therefore essential to optimize and select the right material for each component in the bogie suspension system. This paper deals with the material selection and testing of one such component - Bogie Wear Pad. The bogie wear pad undergoes sliding friction throughout its lifetime during loading and unloading of bogie suspension. Three different materials are selected and their wear is measured under the same conditions of loading. The horizontal and vertical loads acting on the wear

Paul, Thomas, Siva Kumar, Natarajan, R, Suresh, Narasimman, Obuli Karthikeyan, N, Gopi Kannan

MULTI-ENVIRONMENT ACCELERATED DURABILITY TEST FOR EXHAUST SYSTEM FLANGE JOINTS

2021-26-04729/22/2021

Accelerated testing is vital to meet stringent project timelines and is a key consideration for developing new testing methodology. Specifically, durability testing is one of the key fields of interest to deal with all aspects. Fatigue with exposure to multiple environments is a major cause of exhaust system flange joint failure. Physical verification of increased design life expectancy, demands longer testing time, while shorter time to market is main differentiator for competitiveness. Government policy induced timeline pressures added to the need of accelerated tests. The methodology described in this paper embraces these aspects to ensure a quicker flange joint testing, with due consideration to environmental impact. Until the BSVI norms, marginal leakage through the system joints was usual and acceptable. Stringent emission norms demand ‘near-zero’ leakage from exhaust systems. The system joints essentially being the most probable leakage zones, became the focus area

Dhumal, Sagar Prakash, Suryawanshi, Sachin, Mone, Manasi

Monitoring Brake Wear with Acoustics

2021-01-10538/31/2021

A new approach for detecting problems with vehicle brakes by analyzing sounds emitted during braking events is proposed. Vehicle brakes emit acoustic energy as part of the braking process; the spectra of these sounds are highly dependent on the mechanical condition of the brake and can be used to detect problems. Acoustic theory indicates that as brake linings wear thinner the resonant frequency of the shoe or pad increases, potentially enabling the monitoring of lining wear through passive acoustic sensors. To test this approach, passive acoustic sensors were placed roadside at the exit of a transit bus facility for 9 months. The sensors collected almost 10,000 recordings of a fleet of 160 vehicles braking over a variety of conditions. Spectra of vehicles that had brake work performed during this period were analyzed to compare differences between new and worn friction linings. It was found that the spectra changes as friction linings wear, in concurrence with acoustic theory, where

Hearing, Brian, Grove, Kevin, Alden, Andrew

Abrasion Resistance Testing - Vehicle Exterior Graphics and Pin Striping

J1847_202101 (Current)

1/7/2021

This SAE Recommended Practice applies to the abrasion resistance testing of decorative tapes, graphics, and pin striping. It may also have relevance to certain vehicle labels and plastic wood grain film. The resistance to abrasive damage is judged qualitatively by its effect on the legibility, pattern, and color of the graphic marking. This recommended practice is intended as a guide toward standard practice but may be subject to frequent change to keep pace with experience and technical advances. This should be kept in mind when considering the use of this recommended practice.

Materials, Processes and Parts Council

Performance Deterioration of Rotorcraft Engines fitted with Particle Separators

F-0076-2020-16335

10/5/2020

Military rotorcraft engines operating in harsh environments routinely ingest large quantities of mineral dust, which can degrade components and ultimately reduce operability. Time off-wing for unscheduled maintenance is a costly burden, both financially and operationally. Rapidly predicting engine deterioration rates as a function of the mission presents an opportunity to optimise flow of supplies, better manage fleets, and perform safety risk assessments when dust loading is expected to be particularly high. In the current contribution, we present our ongoing efforts in this field with a new methodology for assessing the effectiveness of inertial particle separators and quantifying the changes they impart to the inbound dust. We demonstrate that both the concentration reduction and the modification to the particle size distribution can be made on the basis of a single independent variable- a generalised Stokes number for inertial particle separators- and a single performance parameter

Bojdo, Nicholas, Appleton, Wesley, Ellis, Matthew, Filippone, Antonio, Hee, Jee-Loong

Influence of Increasing Amount of Attapulgite on the Performance Properties of Cu-Free Brake-Pads

2020-01-160110/5/2020

Copper is almost inevitable functional filler in the brake-material and efforts to replace it are continuing since it is now known as a hazard to the aquatic life. It is always desirable to search for ingredients for Cu-free brake-pads, which will be beneficial for friction-related properties and especially fade resistance. Attapulgite, is a mineral which was proven to be an excellent substitute for asbestos in brake-pads long back. However, hardly anything in details is reported on its exact role in controlling tribo-properties of friction materials (FMs). It was of interest, if it can be helpful in enhancing the performance of Cu-free FMs. Hence, in this work a series of brake-pads (five types) was formulated and developed with increasing amount of attapulgite (0, 5, 10 and 15 wt. %) by compensating with inert barite particles in Cu-free FMs. The parent composition was fixed and instead of Cu powder, 10 wt.% stainless steel powder was used. One more type of pads was also developed

Bhatt, Bhaskar, Kalel, Navnath, Abdel-Latif, May, Bijwe, Jayashree

Controlling the Performance of Copper-Free Brake-Pads by Varying Size of Graphite Particles

2020-01-160410/5/2020

Graphite plays a crucial role in friction materials, since it has good thermal conductivity, lubricity and act as a friction modifier. The right type, amount, shape, and size of the particles control the performance of the brake-pads. The theme of the study was investigating the influence of size of graphite particles (having all other specifications identical) on performance properties of brake-pads containing graphite particles in the average size of 60 μm, 120 μm, 200 μm and 400 μm. Physical, mechanical and chemical characterization of the developed brake-pads was done. The tribological performance was studied using a full- scale inertia brake dynamometer following a Japanese automobile testing standard (JASO C406). Tribo-performance in terms of fade resistance, friction stability and wear resistance were observed best for smaller graphite particles. It was concluded that smaller size serves best for achieving best performance properties barring compressibility.

Singh, Sandeep, Kalel, Navnath, Darpe, Ashish, Gilardi, Raffaele, Bijwe, Jayashree

Wear Performances of Gray Cast Iron Brake Rotor with Plasma Electrolytic Aluminating Coating against Different Pads

2020-01-162310/5/2020

Gray cast iron brake rotor experiences substantial wear during braking and contributes largely to the wear debris emissions. Surface coating on the gray cast iron rotor represents a trending approach dealing with the problems. In this research, a new plasma electrolytic aluminating (PEA) process was used for preparing an alumina-based ceramic coating with metallurgical bonding to the gray cast iron. Three different types of brake pads (ceramic, semi-metallic and non asbestos organic (NAO)) were used for tribotests. Performances of PEA coatings vs. different brake pad materials were comparatively investigated with respect to their coefficients of friction (COFs) and wear. The PEA-coated brake rotor has a dimple-like surface which promotes the formation of a thin transferred film to protect the rotor from wear. The transferred film materials come from the wear debris of the pads. The secondary plateaus are regenerated on the brake pads through compacting wear debris of the pads. The wear

Cai, Ran, Zhang, Jingzeng, Tjong, Jimi, Nie, Xueyuan

A Comparative Study On-Dynamometer Performance Evaluation of Fly Ash Containing Non Ferrous Organic and Low-Metallic Disc Brake Pads for Passenger Vehicles and Thereby Promoting a Very Cheap Inorganic Filler Available in Abundance

2020-01-161310/5/2020

A number of functional and non- functional fillers are invariably used for friction material composites. In recent years disposal of fly ash has been a big challenge due to low availability of damping sites. Current work investigates the characterization of Low -metallic and Organic composites made with fly ash with variable concentrations and evaluated for braking performance (SAE J2522) & wear (SAE J2707) on a brake inertia dynamometer. Composites have been characterized for their physical, thermal, mechanical and tribological performance. Low-metal based composites (LMBC) have shown better thermal resistance than non-ferrous organic formulation based composites (NFOC). Mechanical properties such as hardness, shear strength and compressibility have been found to be similar for both the composites. NFOC composites have shown better wear resistance while acquiring slightly lower coefficient of friction values. Load-speed sensitivity of the composites has been further investigated to

Tomar, Bharat Singh, Ali, Sharafat, Ellis, Keith, Choudhary, Yogesh

Changing Properties of Brake Pads and Discs during Brake Testing

2020-01-162810/5/2020

Earlier publications show that brake pad physical properties such as hardness, modulus and natural frequencies continue to increase at room temperature over a period of 12 months and that the changes are faster during the first 3 - 6 months. The current investigation was undertaken to see how the properties might change during testing for the pads as well as for the discs. Low-copper and copper-free formulations were tested on pickup truck and passenger car brakes. In all cases, the dynamic modulus and natural frequencies are found to decrease (not increase) after the SAE J2522 performance testing, indicating that the stiffness of the pad and that of the disc decrease faster than the mass loss due to wear. Also, the inboard pad and the outboard pad change at two different rates. Questions arise on what properties to measure for quality assurance and when to measure in light of these changing properties as well as the fact that the relationship between the initial properties and the

Sriwiboon, Meechai, Tiempan, Nipon, Kaewlob, Kritsana, Rhee, Seong Kwan

An Investigation of the Role of Wear and Friction Film Influencing the Friction Coefficient of Brakes: Mechanism of Brake Fade

2020-01-163010/5/2020

Commercial heavy truck drum linings of 4 different compositions were tested using the Chase tester under constant loads and temperatures at a constant speed in order to find out how lining wear might affect the friction coefficient. When the lining wear increases, the friction coefficient increases linearly under a condition of constant load, speed and temperature. However, when the lining wear approaches zero, the friction coefficient still remains relatively high, indicating other factors are also involved in controlling friction such as interface deformation and others. As the temperature increases or the load increases, the wear contribution to the friction becomes less and less effective. All these observations are discussed and explained in terms of wear particle formation and friction film behavior.

Rhee, Seong, Sharma, Devendra, Singh, Shiv Raj, Rathee, Aman

The Tribological Behavior of the DLC-Coated Engine Surfaces Lubricated with Oils with Nanoadditives

2020-01-21599/15/2020

Nowadays, it is commonly strived to achieve the highest efficiency of internal combustion engines and the longest possible inter-repair millage conditioned by low wear of engine components. This needs the reduction of the friction and wear intensity for the mating surfaces of engine components. This is commonly achieved by using the right oil, its additives and coating the surface with protective layers. Various nanoparticles, such as TiO2, ZrO2, CuO can be added to the base oil to change lubricating properties and creating so-called nano-oils. Parallelly, mating engine surfaces are often covered with very thin DLC coatings. Lubrication of DLC-coated surfaces with nano-oil can create both positive and negative synergy effects. The goal of the present review is to recognize the state-of-art in terms of existing types of DLC coatings and techniques for their application, types of nanoparticles dispersible in engine oils and the tendency to create a synergistic effect in contact zones.

Jozwiak, Piotr, Siczek, Krzysztof, Batory, Damian

Impact of Using Residual Fuels on the Wear of Selected Elements of Self-Ignition Internal Combustion Engines

2020-01-21039/15/2020

The article presents the results of research on the impact of fuel type on the consumption of selected, components and piston nodes of internal combustion engines. The objects of research are medium-speed piston self-ignition engines, which drive generators feeding by residual fuels. Engines, powered by residual fuels was subject to intensive wear, as the fuels contained significant amounts of sulfur and water and are characterized by a high Conradson number. Wear has been examined under various natural operating conditions, including those prevailing in tropical regions. Significant wear has been found of combustion chamber elements, such as cylinder liners, pistons, cylinder heads, timing valves and injection apparatus. The wearstates of selected elements has been compared to the degree of supply of distillation fuels. Intensive wear of the investigated engines under analysis results from their design, where the lubrication system of pistons and sleeves and is not separated from that

Monieta, Jan

Experimental Study of Tread Rubber Compound Effects on Tire Performance on Ice

02-13-02-0006

6/16/2020

Mechanical and thermal properties of the rubber compounds of a tire play an important role in the overall performance of the tire when it is in contact with the terrain. Although there are many studies conducted on the properties of the rubber compounds of the tire to improve some of the tire characteristics, such as the wear of the tread, there are a limited number of studies that focused on the performance of the tire when it is in contact with ice. This study is a part of a more comprehensive project looking into the tire-ice performance and modeling. In this study, to understand the effect of different rubber compounds on the tire performance, three identical tires from the same company have been chosen. The tires’ only difference is the material properties of the rubber. Two approaches have been implemented in this study. For the first approach, several tests were conducted for the chosen tires at Terramechanics, Multibody, and Vehicle Systems (TMVS) laboratory at Virginia Tech to

Mousavi, Hoda, Sandu, Corina

Solenoid Valve Health Monitor

TBMG-370056/1/2020

The Solenoid Valve Health Monitor System (SVHMS) was developed to remotely monitor the health of solenoid valves, lowering operational costs and increasing reliability by predicting valve failures before they occur. The system measures and analyzes steady state and transient components of the magnetic field and indirectly, the electric current in a solenoid valve during normal operation. It enables continuous monitoring of the integrity and operational status of solenoid valves without the need for interrupting their operation to conduct frequent inspections.

Advances in Drilling with PCD (Polycrystalline Diamond)

2020-01-00353/10/2020

PCD properties were optimized to drill stacks of CFRP/Ti using an accelerated wear test milling gray cast iron. The optimized PCD was then used to prepare PCD drills. Tests were made to determine the best drilling conditions for the optimized PCD. The results yielded a significant improvement in cycle times as compared to earlier studies using PCD drills. Notched PCD cutting edges were found to eliminate oversizing of the CFRP near the interface of the two materials.

Bunting, Jeremy, Bunting, John

Tool Wear Analysis on Drilling Process of Inconel 718 Superalloy

2020-01-00343/10/2020

The Inconel 718 is an alloy based on nickel of high thermal and mechanical resistance, which allows its wide application in the aerospace industry, being generally implemented in aircraft tail cone and engine components. On the other hand, these features become a recurring problem when the machining of this material is performed. For example, in the drilling process of this superalloy, the cutting tools used exhibit excessive wear due to the high temperature and pressure at the cutting edge. However, there are numerous parameters that can influence the cutting tool life, and when analyzed and well defined, determine the types of modifications needed to enable less wear, and consequently an increase of its useful life in service. Given this context and knowing that the study of tool life in the Inconel 718 drilling process is extremely relevant in the aerospace sector, this paper presents a wear study in order to evaluate the behavior of different types of cutting tools used to drill

Barros, Pedro Cabegi, Barbosa, Gustavo Franco, Ventura, Carlos Eiji Hirata, Santos, Gustavo Roberto

Advances in Drilling with PCD (Polycrystalline Diamond)

2020-01-00353/10/2020

Bunting, Jeremy, Bunting, John

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