View of WEAR ANALYSIS OF BRAKE PAD & FRICTION LINING MATERIAL ON PIN ON DISC APPRATUS FOR ENHANCING LIFE OF BRAKING SYSTEM

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Vol.04, Issue 12, December 2019, Available Online: www.ajeee.co.in/index.php/AJEEE WEAR ANALYSIS OF BRAKE PAD & FRICTION LINING MATERIAL ON PIN ON DISC

APPRATUS FOR ENHANCING LIFE OF BRAKING SYSTEM

1Akash Kumar Pasi, ¹Scholar-Ggits Jabalpur

2Prof. Pragyan Jain, ²HOD, ME, GGITS Jabalpur, MP, India

Abstract:- The aim of this study to investigate the viability of Brake system for prolong and effective life. The common market available Braking discs are evaluated with respect to time and material erosion rate at different speed and pressure. In this study I use the same base material of brakes, to find the Best possible option of the braking pads available in the market. It was also important to Optimized the life of Pads for different velocity in practice so wear test was conducted on different load conditions. To Enhance matrix strength of brake pad material graphene dust and Virgin carbon powder was blended with the base brake pad material at elevated temperature. Again, wear test and SEM test were conducted to investigate the improved properties of pad materials. The wear tests were carried out in a pin-on-disc wear-testing machine, the pin being manufactured from friction material usually used in light truck brake pads. The rotating discs (500 rpm) were subjected to cyclical pressures of 15, 30 and 100 kPa. The wear was measured by weighing discs and pads before and after the test. The operating temperatures and friction forces were also monitored during each test.

1. INTRODUCTION

Wear is the part of machine design. This thesis is basically done for reducing the wear of the machine part and to increase the life of the product as well as to achieve the desired mechanical properties of the machine component by means of coating. Here coating is a variable for achieving the goal.

1. Matteo Federici, Giovanni Straffelini, Stefano Gialanella “Pin-on-Disc Testing of Low-

Metallic Friction Material Sliding Against HVOF Coated Cast Iron: Modelling of the Contact

Temperature Evolution” Tribol Lett (2017) 65:121

Matteo Federici et. al Presented the transient thermal analysis of a pin made with a friction material dry sliding against HVOF coated and uncoated pearlitic cast iron disc in a PoD apparatus was investigated by means of a finite element analysiS together with experimental measurements.

2. G. Pantazopoulos, A. Tsolakis, P.

Psyllaki, A. Vazdirvanidis “Wear and Degradation Modes in Selected Vehicle Tribosystems” Tribology in Industry International Tribology

Conference BALKANTRIB, Vol. 37, No. 1 (2015) 72-80

G. Pantazopoulos et al presented the wear and degradation mechanisms of two principle vehicle tribo systems to elucidate the main causes of their premature failure.

3. Matteo Federici, Stefano Gialanella, Mara Leonardi, Guido Perricone, Giovanni Straffelini “Apreliminary investigation on the use of the pin-on-disc test to simulate off brake friction and wear characteristics

of friction materials.”

www.elsevier.com/locate/wear.

Matteo Federici et. al. addressed the frictional behavior of 5 commercial low- met and NAO friction materials dry sliding against a cast iron counterface disc, under low contact pressures, typical of offbrake driving.

4. D. Catic, J. Glišovic , J. Mikovic, S.

Velickovic “Analysis of Failure Causes and the Criticality Degree of Elements of Motor Vehicle’s Drum Brakes” Tribology in Industry Vol. 36, No. 3 (2014) 316-325.

D. Catic et. al. established a causal relation between the different events that lead to a reduction in performance or complete failure of the braking system.

5. M Ungureanu, N S Ungureanu and I Craciun “Study on friction behaviour of brake shoe materials for mining hoist”

13th International Conference on Tribology, ROTRIB’16 Materials Science and Engineering 174 (2017) 012016.

6. Faramarz Talati Æ Salman Jalalifar,

“Analysis of heat conduction in a disc brake system” July 2008 / Accepted: 5 January 2009 / Published online: 27 January 2009, Springer-Verlag

2009. Faramarz Talati et. al. derived governing heat equations for the disc and the pad in the form of transient heat

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Vol.04, Issue 12, December 2019, Available Online: www.ajeee.co.in/index.php/AJEEE equations with heat generation that is

dependant to time and space.

7. Sadiq Sius LAWAL, Katsina Christopher BALA, and Abdulkareem Tunde ALEGBEDE

“Development and production of brake pad from sawdust composite” Leonardo Journal of

Sciences ISSN 1583-0233 Issue 30, January-June 2017 Sadiq Sius LAWAL et.

al. presented research work on new alternative materials for brake pad.

8. Guoshun Wang and Rong Fu “Impact of Brake Pad Structure on Temperature and Stress

Fields of Brake Disc” Hindawi Publishing Corporation Advances in Materials Science and

Engineering, Volume 2013, Article ID 872972

Guoshun Wang and Rong Fu utilized ABAQUS finite element software, established the relationship between a brake pad structure and distributions of temperature and thermal stress on brake disc.

Pin on Disc Wear tester:

 The pin-on-disc wear test is performs to measure the lifetime of the coating.

 The instrument used for this purpose is known as Tribo-meter as shown in figure below.

 The sample is mounted on a rotary disc which can be rotated at a predetermined speed and a pin or other static element is mounted in contact with the rotating sample via an elastic arm which can move laterally and therefore measure the tangential forces (friction force) between sample and pin with the help of sensor.

 The whole data is records the frictional force as a function of time or number of revolutions, and then these all data will be calculated.

 When test is completed the actual wear rate of sample and other element can be calculated.

1.1 Objective Of Study

Objective of the study to Find:

A. Best possible option of the braking pads available in the market

B. Optimized the life of Pads for different velocity

C. Enhancing matrix strength of brake pad

 Market Players in brake Pads

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Vol.04, Issue 12, December 2019, Available Online: www.ajeee.co.in/index.php/AJEEE

 Bosc, Brakes India Pvt. Ltd.,

 Brakewel Automotive Components India Pvt. Ltd,

 Hindustan Composites Limited,

 Makino Auto Industries Pvt.

Ltd.

 Ranbro Brakes India Limited,

 Rane Brake Lining Limited,

 Sundaram Brake Linings, 2. MATERIAL FOR BRAKES IN INDIA

Disc Material Category

C Si Mn S P Fe

Low Carbon

3.0-3.4 1.9-2.2 0.5-0.8 0.10 max 0.10 max rest Medium

Carbon 3.3-3.5 1.9-2.2 0.5-0.8 0.10 max 0.10 max rest High

Carbon 3.6-3.9 1.8-2.1 0.5-0.8 0.10 max 0.10 max rest Alloys - Molybdenum = 0.3 - 0.5%, Chromium =

0.2 - 0.4%, Nickel = 0.1 - 0.3%,

Copper = 0.5 - 0.8% , Titanium = 0.02 - 0.04%

Time vs Wear rate, Market Survey

Market Findings

Figure shows the variation of wear with respect to time in same base material of brake pads of 3 reputed companies i.e.

Bosc, Brakes India Pvt. Ltd., Hindustan Composites Limited, Sundaram Brake Linings at a constant load of 30KPa. It was observed that among these three samples of brake pads, wear rate was found minimum in sundaram brakes linings. Hence it is selected for the further study.

Sample preparation

Samples were characterized by SEM and wear test.

1. Disc is prepared by pearlitic gray cast iron alloy. Specification of disc are:- Diameter of the disc, D = 165mm Thickness of the disc, t = 8mm 2. Newly purchased brake shoe pad are cut in specified dimensions Width, w = 10 mm

Length, l = 10 mm Thickness, t = 5 mm 3. METHODOLOGY

Steps are followed in presented work 1. Market analysis for sustainability 2. Sample formation for wear tester

and SEM

3. Wear Testing for different velocities and different loading conditions 0

10 20 30 40 50 60 70 80 90

0 1000 2000 3000 4000

Bos c, B rak es In…

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Vol.04, Issue 12, December 2019, Available Online: www.ajeee.co.in/index.php/AJEEE 4. Selection of best brake pad

sample.

5. Coating on pad

6. Wear testing on coated sample 7. SEM testing on wear out sample

SEM test was carried out at IITDM, Jabalpur by using JEOLJSM-6380A analytical Scanning Electron Microscope

Figure No.10: SEM v JEOLJSM-6380A SEM Instrument 4. DISCUSSION

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The microstructure image of cast iron at 15 KPa, 30KPa and 50 KPa 4.1 Interpretation of SEM

Figure shows the microstructure image of cast iron at 15 KPa, 30KPa and 50 KPa.

Small groove can easily seen at 15 KPa microstructure along with foreign particle of pad material. The cast iron disc shows pearlite and ferrite microstructure along with graphite flank. During operation on road condition wear track appears on the disk. Due to the friction removal of

graphite from the disc surface takes place. As load increases, depth of wear tracks increases removal of graphite rate increases. Tribo-oxide layer prevents the wear. Black spot shows the formation of tribo-oxide layer. With the increment in load depth and width of groove increases.

results clearly indicates that at low load disc shows minimum wear rate which prevents the damage in disc.

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Figure shows the variation of wear with respect to time. It was observed that initially wear increases at very fast manner upto 1000 sec, after that wear rate decreases and finely after 3000 sec at

almost get stable. Wear is the function of load so at 50 KPa pressure wear is very high whereas it decreases with load decreases at 15KPa pressure wear rate was found minimum.

COF at different loads are shown in figure-3 Initially COF increases with very fast rate due to less contact between pin and disc (cast iron plate and friction material) high stresses induced in contact zone, so it result as increasing wear at fast manner. As contact surfaces increases COF Decreases. COF decreases due to contact temperature in contact zone tribo oxide film developed in contact zone. This tribo film prevents the further wear results as constant COF identified after 200 sec.

5. CONCLUSION

Enhancement in the wear properties of the pad material. The following conclusion were made: -

 Provides highest bond integrity due to blending of graphene dust and Nusselt carbon powder.

 Wear increases with time. Less wear rate was found in blended sample.

 Minimum wear found at 15 KPa applied load. At higher load wear shows an increasing trend.

5.1 Future Scope

 In this work wear properties of pad material were improved, in future following investigations will be required to reliable designing of braking system.

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 The disc material properties would also be considered for the investigation. So, the life of the braking system could be improved.

REFERENCES

1. Matteo Federici, Giovanni Straffelini, Stefano Gialanella “Pin-on-Disc Testing of Low- Metallic Friction Material Sliding Against HVOF Coated Cast Iron: Modelling of the Contact Temperature Evolution”

Tribol Lett (2017) 65:121

2. G. Pantazopoulos, A. Tsolakis, P. Psyllaki, A. Vazdirvanidis “Wear and Degradation Modes in Selected Vehicle Tribosystems ” Tribology in Industry International Tribology Conference BALKANTRIB, Vol.

37, No. 1 (2015) 72-80

3. Matteo Federici, Stefano Gialanella, Mara Leonardi, Guido Perricone, Giovanni Straffelini “A preliminary investigation on the use of the pin-on-disc test to simulate off brake friction and wear characteristics

of friction materials.”

www.elsevier.com/locate/wear

4. Catic, J. Glišovic , J. Mikovic, S. Velickovic

“Analysis of Failure Causes and the Criticality Degree of Elements of Motor Vehicle’s Drum Brakes” Tribology in Industry Vol. 36, No. 3 (2014) 316-325.

5. M Ungureanu, N S Ungureanu and I Craciun “Study on friction behaviour of brake shoe materials for mining hoist” 13th International Conference on Tribology, ROTRIB’16 Materials Science and Engineering 174 (2017) 012016.

6. Faramarz Talati Æ Salman Jalalifar,

“Analysis of heat conduction in a disc brake system” July 2008 / Accepted: 5 January 2009 / Published online: 27 January 2009, Springer-Verlag 2009.

7. Sadiq Sius LAWAL, Katsina Christopher BALA, and Abdulkareem Tunde ALEGBEDE “Development and production of brake pad from sawdust composite”

Leonardo Journal of Sciences ISSN 1583- 0233 Issue 30, January-June 2017.

8. Guoshun Wang and Rong Fu “Impact of Brake Pad Structure on Temperature and Stress 30 Fields of Brake Disc” Hindawi Publishing Corporation Advances in Materials Science and Engineering, Volume 2013, Article ID 872972.

9. S. R. Kakad, R.M. More, Dr. D. N. Kamble

“Mathematical Modeling & Analysis of Brake Pad for Wear Characteristics”

International Conference on Ideas, Impact and Innovation in Mechanical Engineering (ICIIIME 2017) ISSN: 2321-8169.

10. G. P. O STERMEYER, “Modeling Friction And Wear Of Brake Systems.” German.