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Genesis of the Third-Body at the Pad-Disc Interface: Case Study Of Sintered Metal Matrix Composite Lining Material

SAE International Journal of Materials and Manufacturing

Ecole Centrale de Lille-Yannick Desplanques, Gérard Degallaix
  • Journal Article
  • 2009-01-3053
Published 2009-10-11 by SAE International in United States
During braking, third-body flows and layers govern friction mechanisms, which are fully responsible of the friction coefficient and wear. In the context of development of brake friction pairs, the involved tribological circuit has to be well understood and mastered. This paper concerns a sintered metal matrix composite used for TGV very high speed train. A series of low-energy stop brakings allows a detailed study of the third-body formation at the pad-disc contact. The pin surface is observed after each test. The evolution of the rubbing-area expansion all along the series is explained, and the friction behaviour, typical of the studied friction material, is related to the formation of a well-established third body at the pad-disc interface.
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Application of Extension Evaluation Method in Development of Novel Eco-friendly Brake Materials

SAE International Journal of Materials and Manufacturing

Beijing University of Chemical Technology-Rongping Yun, Yafei Lu
Southern Illinois University Carbondale-Peter Filip
  • Journal Article
  • 2009-01-3019
Published 2009-10-11 by SAE International in United States
Extenics is a new cross discipline to study rules and methods of solving contradictory problems in the real world. The basic concepts and theoretical frame of extenics are briefly introduced in this paper. Based on the merit of extenics, the extension evaluation method was applied to evaluate the brake materials according to a five-grade criterion established in this study. Considering the results computed by the original and simplified models, the similar conclusions were made: all four brake samples, marked A - D, were evaluated in the first grade based on the calculated dependence degrees, and sample B was judged as the best performing friction material with the highest dependence degree and the lowest wear rate. The preliminary results verify that it is feasible to apply the extension evaluation method for the development of friction materials, and the five-grade criteria established in this study can be applied for analyzing the results of the Friction Assessment and Screening Test (FAST) scientifically.
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Sphere-To-Cone Mating – New Solution to Improve Brake Tube Connector Sealing Robustness

SAE International Journal of Materials and Manufacturing

Stanislav I. Pliassounov
  • Journal Article
  • 2009-01-3024
Published 2009-10-11 by SAE International in United States
Recently invented solutions (Canadian Patent 2593305 and United States Patent Applications 20090015008 and 20070194567) incorporate sphere-to-cone type of the interaction between sealing surfaces in a brake tube connector. An interaction of sphere-to-cone type has numerous advantages over one with a cone-to-cone type which is currently utilized in conventional automotive brake tube connectors. Incorporation of a sphere-to-cone interaction between the sealing surfaces dramatically improves connector's sealing robustness. Sphere-to-cone based connectors are resilient to the tube and seat axes misalignment. Correspondingly, sphere-to-cone based connectors have less variation of the securing torque and virtually no propensity to locked misalignment occurrence. The article analyzes another fundamental advantage of a sphere-to-cone mating over the conventional cone-to-cone one. The analysis reveals that sphere-to-cone type of interaction demonstrates approximately one order of magnitude (10 times) less sensitivity to common dimensional variation. A Robust Design approach has been utilized for sealing capability analysis and comparison. The transfer functions with respect to the sealing capability of both current cone-to-cone based connectors and new sphere-to-cone based connectors have been obtained and compared. The comparison suggests…
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Effects of Chemical Components and Manufacturing Process of Cast Iron Brake Disc on its Resonant Frequency Variation

SAE International Journal of Materials and Manufacturing

Hyundai & Kia Corporate Research & Development Division-Jae Young Lee, Hyun Dal Park, Seong Jin Kim, Jae Min Han, Yoon Cheol Kim, Jong Dae Lim, Jeong Kyu Kim
  • Journal Article
  • 2009-01-3030
Published 2009-10-11 by SAE International in United States
Many engineers have been working to reduce brake noise in many ways for a long time. So far, a progress has been made in preventing and predicting brake noise. Nevertheless, there are some discrepancies of brake noise generation propensity between testing for the prototype and the production. As known in general, the reason for this unpredicted brake noise occurrence in production is partly due to the variation of the resonant frequency, material and the other unpredictable or unmanageable variations of the components in a brake system. In this paper, effects of chemical components and casting process of gray iron brake disc on its resonant frequency variation have been studied. Especially this paper is focused on the variation in material aspects and manufacturing parameters during disc casting in usual production condition. And their effects are investigated by the variation of out-of-plane modal resonant frequency.
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