Sustainable Biocomposites Materials for Automotive Brake Pad Application:An Overview

Research into converting waste into viable eco-friendly products has gained global concern.Using natural fibres and pulverized metallic waste becomes necessary to reduce noxious environmental emissions due to indiscriminately occupying the land.This study reviews the literature in the broad area of green composites in search of materials that can be used in automotive brake pads.Materials made by biocomposite,rather than fossil fuels,will be favoured.A database containing the tribo-mechanical performance of numerous potential components for the future green composite was established using the technical details of bio-polymers and natural reinforcements.The development of materials with diverse compositions and varying proportions is now conceivable,and these materials can be permanently connected in fully regulated processes.This explanation demonstrates that all of these variables affect friction coefficient,resistance to wear from friction and high temperatures,and the operating life of brake pads to varying degrees.In this study,renewable materials for the matrix and reinforcement are screened to determine which have sufficient strength,coefficient of friction,wear resistance properties,and reasonable costs,making them a feasible option for a green composite.The most significant,intriguing,and unusual materials used in manufacturing brake pads are gathered in this review,which also analyzes how they affect the tribological characteristics of the pads.

Application Research on Self-healing Technology with Microcapsules for Automobile Brake Pad

In order to improve the performance of non-asbestos composite auto brake pads that are composed of matrix resin, reinforced material and fillers, a novel method with new technology of self-heal microcapsules was proposed. Nano reinforced fillers＇ effects were also considered in the experiment project. Five recipe designs for new composite auto brake pads were carried out and cor-responding samples were prepared as well. The friction coefficient and wearing properties at certain temperature, impact intensity and hardness were comparatively studied. Investigations indicate that properties of such composite auto brake pads meet the requirements of the national standards while microcapsule＇s weight content varies from 5.5wt%-1.09wt% of matrix resin and microcapsule＇s loca-tion varies in the pads. Nano reinforced fillers have the effects of increasing composites＇ impact in-tensity and hardness. Application of self-healing microcapsules in auto brake pads is feasible.

Reliability Evaluation of CRH_(3C) Brake Pads Based on Bayes Method

In the reliability life evaluation of CRH_(3C) brake pads,the evaluation model of reliability life is put forward based on the Bayes method in the small sample. The correctness of evaluation model is validated by comparing and analyzing with the evaluation results based on Bootstrap simulation. Also by comparing the result with the semi-empirical method,the life evaluation results of the brake pads which are based on the Bayes method are more actual. The results which are based on the Bayes method can provide the theoretical basis and guidance for the repair and replacement of brake pads.

Experimental investigations on wear properties of Palm kernel reinforced composites for brake pad applications

The use of asbestos material is being avoided to manufacture the brake pads as it is harmful and toxic in nature. Further it leads to various health issues like asbestosis, mesothelioma and lung cancers. These brake pads can be replaced by natural fibers like Palm kernel (0-50%), Nile roses (0-15%) and Wheat (0-10%) with additives like aluminum oxide (5%-20%) and graphite powder (10%-35%). Phenolic resin of 35% is utilized as a binder. Particulated Nile roses are used to increase the friction coefficient and wheat powder is used to reduce the wear rate. Aluminum oxide and graphite are abrasive in nature. This helps to make brake pads with high friction co-efficient and less wear rate with low noise pollution. The wear of the proposed composites have been investigated at different speeds. Various tests like wear on pin-ondisc apparatus, hardness on the Rockwell hardness apparatus and oil absorption test have been conducted. Phenolic resin produces good bonding nature to fiber. Thus, Fibers found to have performed palatably among all commercial brake pads. The objective of the research indicates that Palm kernal shell could be a conceivable alternative for asbestos in friction coating materials.

Mechanical Properties of Powder Based Steel used as Backing Plate in Heavy Duty Brake Pad Manufacturing

The aims of the present study is to develop a powder based steel used as backing plate for heavy duty brake pad applications. Three powder based back plate steel compositions namely B1 (C- 0.3, Cu – 1.5, P -0.3, Fe – 97.9), B2 (C- 0.1, Cu – 2.5, SiC-1, Fe – 96.4) and B3(C- 0.5, Cu – 2.5, SiC-1, Fe – 96.0) were prepared using a hot powder preform forging technique. The forged samples are of (25× 50×10 mm3) dimensions. These samples were hot rolled and annealed to relieve the residual stresses. These samples were characterized in terms of microstructure, porosity content/densification, hardness and tensile properties. Densification as high near to theoretical density has been realized. Hot powder preform forging using closed die showed better densification. Rolled and annealed microstructure showed lesser porosity content than the forged one. Phosphorous causes hardening of ferrite in solid solution with iron. Compositions B1, showed reasonable elongation and it improved further on annealing. It was observed in this present investigation that, the addition, such as SiC and Cu caused increase in strength. Steel developed in the investigation are used as powder based backing plate in Manufacturing of iron based brake pads used in heavy duty applications.

Rock Magnetic Characterization of Fine Particles from Car Engines, Brake Pads and Tobacco: An Environmental Pilot Study on Oahu, Hawaii, USA

Today, it is well known that small airborne particles are very harmful to human health. For the first time in Hawaii we have conducted an environmental pilot study of fine magnetic particles on the island of Oahu, Hawaii, of particulate matter (PM) PM = 60, PM = 10, and PM = 2.5. In order to do a rock magnetic characterization we have performed low field susceptibility vs. temperature [k-T] experiments to determine the Curie points of small particles collected from exhaust pipes, as well as from brake pads of four different types of car engines using gasoline octane ratings of 87, 89, and 92. The Curie point determinations are very well defined and range from 292°C through 393°C and up to 660°C. In addition, we have conducted magnetic granulometry experiments on raw tobacco, burnt tobacco ashes, as well as on automotive engine exhaust, and brake pads in question. The results of the experiments show ferro and ferrimagnetic hysteresis loops with magnetic grain sizes ranging from superparamagnetic-multidomain [SP-MD], multidomain [MD] and pseudo-single domain [PSD] shown on the modified Day et al., diagram of Dunlop (2002). Thus far, the results we have obtained from this pilot study are in agreement with other studies conducted from cigarette ashes from Bulgaria. Our results could be correlated to the traffic-related PM in Rome, Italy where the SP fraction mainly occurs as coating of MD particles originated by localized stress in the oxidized outer shell surrounding the un-oxidized core of magnetite-like grains. All these magnetic particles have been reported to be very harmful to our human bodies (i.e. brain, lungs, heart, liver etc.).

CNN-LSTM based on attention mechanism for brake pad remaining life prediction

In order to predict the remaining service life of brake pads accurately and efficiently,and to achieve intelligent warning,this paper proposes a CNN-LSTM brake pad remaining life prediction model based on an attention mechanism.The model constructs a non-linear relationship between brake pad features such as brake temperature,brake oil pressure and brake speed and brake pad wear data through convolutional neural network(CNN)and long and short term memory network(LSTM),as well as capturing the time dependence that exists in the brake pad wear sequence.The attention mechanism is also introduced to assign different weight values to the features output from multiple historical moments,highlighting the features with high saliency and avoiding the influence of invalid features,so as to improve the prediction effect of the remaining brake pad life.The results show that the proposed CNN-LSTM-Attention model can effectively predict the remaining life of brake pads,with the mean absolute error MAE value of 0.0048,root mean square error RMSE value of 0.0059 and coefficient of determination R2 value of 0.9636;and compared with the BP model,CNN model,LSTM model and CNN-LSTM model,the coefficient of determination R2 values are closest to 1,with an improvement of 8.26%,5.25%,3.99%and 1.85%respectively,enabling more effective monitoring and intelligent warning of the remaining brake pad life.

高速列车铜基摩擦材料的氧化行为

高速列车铜基摩擦材料在制动过程中,由于摩擦热的产生和耗散,会发生循环氧化。研究铜基摩擦材料在300、400、500、600和700℃下等温氧化50h的氧化行为。结果表明:铜基摩擦材料的氧化行为呈现多阶段特征;Cu、Fe的氧化与氧的扩散共同控制着低温氧化过程,而石墨的氧化在500℃之后占主导作用;Cu的氧化首先形成Cu_(2)O纳米团簇,然后生成CuO纳米线,最后依次转变为细小的和粗大的等轴晶;氧化温度的升高会促进Fe_(2)O_(3)纳米片的生长和致密化;Cu氧化物由于体积膨胀较大,逐渐将Fe氧化物覆盖;石墨烧蚀后形成的连通孔为内氧化提供氧气扩散通道;材料表面氧化层的形成使得表面硬度提高。

摩擦-消音片结构对盘式制动器尖叫噪声的影响研究

针对某汽车盘式制动器存在制动尖叫噪声问题,研究了不同倒角结构的摩擦片、不同阻尼层厚度的消音片,以及两者匹配对制动尖叫噪声的影响,并通过台架试验分别对研究得到的最佳匹配方案和原方案进行噪声测试。研究结果表明,5种不同倒角结构摩擦片中,对称结构的倒角优于不对称结构,不对称结构的倒角解决频率较为集中的单处噪声效果较好,其中,对称直倒角结构降噪效果最好,但易诱发新的噪声;消音片阻尼层厚度逐渐增大时尖叫噪声发生的倾向性呈现先减小后增大的趋势;摩擦片与消音片的合理匹配能有效改善尖叫噪声,对称倒角和不对称倒角结构的摩擦片分别匹配消音片时的降噪趋势相反,其中对称斜倒角结构的摩擦片与阻尼层厚度为0.28 mm的消音片匹配时降噪效果最好,噪声发生度比原方案降低了97.98%。

列车刹车闸片冶金材料成分配比优化研究

为了促进我国列车刹车闸片粉末冶金材料的发展,研究分析了不同增强组元对粉末冶金材料制备的摩擦材料性能影响。研究分析的2种增强组元分别是羰基铁粉和磷铁粉,粉末冶金材料的基体为超细铜粉,润滑组元为镀铜石墨,摩擦组元为铬铁粉。结果显示,时速低于275 km/h时,磷铁粉材料的摩擦系数更高,时速高于275 km/h时,羰基铁粉的摩擦系数更高,时速为350 km/h时,羰基铁粉材料磨损量为0.625 mg/kJ,磷铁粉材料磨损量为1.634 mg/kJ,研究还探讨了磷铁粉及羰基铁粉对列车刹车材料摩擦性能的影响,对我国粉末冶金材料、制备列车刹车闸片的发展具有指导意义。

250 km/h动车组用闸片制动摩擦及噪声特性

利用1∶1台架试验探究了250 km/h城际动车组闸片-盘紧急制动过程中的摩擦及噪声特性。结果表明当速度为50~250 km/h时,摩擦系数受制动速度增长影响较小,而制动压力的增加仅在250 km/h时诱导摩擦系数下降,表明该型闸片具有优异的摩擦系数稳定性。对于噪声特征,5000 Hz以下的噪声占主导地位,而更高频噪声只出现在某些特定的频率段。制动速度的增加会增加制动初期的噪声强度和频率范围,而压力提高则带来相反的抑制作用。高制动压力会促使制动后期高频啸叫的产生。因此,在制动时采用先高压力后低压力的变压力制动方式可能是降低高频制动噪声的方法。

镀铜石墨对铜基制动闸片组织及性能的影响

采用化学镀的方式在鳞片状石墨表面镀铜来改善铜基制动闸片中石墨和铜基体的界面结合,制定了化学镀铜配方及工艺,并研究了4种不同镀液温度对镀铜效果的影响。对镀铜后的石墨进行显微组织观察和能谱分析可知:随镀液温度的升高,镀铜效果先升后降,最好的施镀温度为50℃。用热压烧结法制备出镀铜石墨/铜基制动闸片(FM1)与非镀铜石墨/铜基制动闸片(FM0),并对其进行力学性能、物理性能测试以及制动测试,并采用扫描电镜和能谱仪对制动闸片在制动前后的表面形貌进行观察及分析。结果表明:与FM0相比,FM1中石墨分布更细小均匀,因此样品的致密度较高,硬度、抗压强度和热导率也随之增大。在不同制动初速度下,随制动初速度的提高,两种闸片的摩擦系数均出现先略微增高、后平稳,然后显著降低的趋势,但FM1的摩擦系数总体比FM0的摩擦系数更高且稳定,线磨损率也相对较小。在350 km/h高速制动条件下,由于摩擦热引起的材料表面软化,两种制动闸片的摩擦系数差别不大,都呈现显著下降趋势。

合成摩擦材料在轨道交通领域的应用与发展

合成摩擦材料以其重量轻、摩擦系数稳定、性能可调节性强等优点,成为轨道交通列车制动装置中的关键材料,主要产品应用于制动的合成闸片、合成闸瓦和用于踏面清扫及修形的研磨子。综合概述了合成摩擦材料在我国轨道交通领域的发展历程,详细介绍了3种产品的物理力学性能和摩擦性能特点,并就合成摩擦材料在铁路机车、城市轨道交通列车、动车组列车等轨道交通上的应用实例和发展情况做了分析。基于列车行驶和制动的复杂工况,对合成摩擦材料在使用过程中常见的金属镶嵌、裂纹、异常磨耗等问题进行成因剖析并提出解决策略。面对轨道交通“提速、重载、轻量化、安全”的发展趋势,提出合成摩擦材料在深化基础理论研究、更高速度等级应用及摩擦副匹配关系等方向的发展需求,为我国在合成摩擦材料的研究及应用提供参考和思路。

刹车片颗粒及其主要成分硫化锑呼吸暴露对小鼠健康危害研究

目的研究刹车制动来源颗粒物对机体的潜在危害。方法研磨刹车片颗粒、硫化锑颗粒,小鼠通过气管灌注暴露1个月后,观察肺、心脏、肝等内脏器官病理改变,同时用流式细胞术分析外周血巨噬细胞和自然调节T淋巴细胞(regulatory T cell,Treg)的变化。结果刹车片颗粒及硫化锑颗粒暴露小鼠肺泡壁外源物质沉积,血管周围出现明显的炎症细胞浸润并随着暴露浓度的增加而加重,同时可出现心脏血管炎症和微血栓以及肝细胞肿胀等病理改变;Treg细胞减少,硫化锑组和低剂量刹车片组巨噬细胞增加,同时M2型巨噬细胞比例下调。结论刹车片颗粒及其成分硫化锑颗粒暴露对小鼠肺、心脏、肝等脏器具有不同程度的毒性作用,并对免疫系统造成了影响,提示刹车来源的空气污染存在潜在健康危害。

铜基粉末冶金闸片的抗热震性能研究

铜基粉末冶金闸片具有高导热性、优异的摩擦学性能和高适应性,被广泛用于高速列车闸片。本文对粉末冶金闸片进行抗热震试验,模拟闸片在制动过程中的温度变化,并对闸片尺寸、粘接强度及显微组织进行测试分析,以验证铜基粉末冶金闸片的可靠性。结果表明:在宏观角度上(毫米级),经过热震循环后,闸片表面未发现明显裂纹;闸片的整体尺寸均有所增加,在低温循环阶段,尺寸增长较慢,高温循环后,急剧增加;在微观角度上(微米级),闸片背板和钎料层结合较好,界面较平直,与摩擦块无明显界面;经热震循环后,摩擦块内部组织变得疏松,与钎料层的结合程度下降。

市域快线分相区设置及控车策略对车辆制动闸片磨耗影响研究

文中主要介绍了国内某城市市域快线车辆轮盘制动闸片磨耗率偏高问题,通过对比分析同型号车辆在不同线路运行期间闸片磨耗差异原因,确定列车通过分相无电区期间施加纯空气制动是闸片磨耗率偏高的关键因素,对此,文中提出了信号控车策略优化方案,评估了优化方案的预期效果,并为后续新建线路分相区设置和信号控车策略设计给出参考建议。

工业机器人打磨刹车片支架仿真加工

刹车片支架在铸造后表面会出现毛刺等缺陷,影响使用性能。设计了工业机器人打磨刹车片支架的夹具,应用RobotArt软件进行仿真加工,以验证打磨轨迹规划的合理性和使用工业机器人打磨刹车片支架的可行性。

浅析天然复合材料在汽车刹车片中的应用

刹车片是汽车的重要部件,其中摩擦学性能是主要关注点。传统上使用的是石棉刹车片,后来被铜基材料取代。随着刹车衬里材料的发展,合成摩擦复合材料被探索作为替代方案。研究表明,香蕉皮、棕榈仁和棕榈渣等天然纤维可有效替代传统刹车片材料。本文分析了天然纤维主要优势、石棉材料和天然纤维的生命周期评估、天然纤维对刹车片性能的影响、天然复合材料刹车片的制造及主要表征。

浅谈后制动卡钳设计规范要求

文章简要介绍后制动卡钳设计规范要求,在满足法规要求下,优化后制动卡钳设计的过程。通过将整车性能参数与后制动卡钳设计的结合,制定后制动卡钳设计策略,在设计后制动卡钳过程中,通过试验测试得出关键技术参数和材料。最后,应用计算机辅助工程(CAE)分析得出,在16 MPa液压下,制动卡钳静强度为280.6 MPa,刚度为0.254 mm;通过对R127.8支架CAE分析得出,在10 MPa液压下,静强度及刚度情况为静刚度302.9 MPa,刚度0.298 mm,研究为汽车行业后制动卡钳设计和优化提供了有价值的参考。

动车组制动闸片基体材料的设计开发

采用机械合金化方法制备特种工况动车组制动闸片的基体材料。以Cu50Fe50混合粉末为研究对象,研究了球磨时间、球磨转速、球料比、球磨介质等因素对材料压制性能的影响。结果表明:随球磨时间的延长,球料比增加,合金化粉末的粒度越小,材料的压制性能逐渐提高;选择无水乙醇作为球磨PCA的粉末表面无“疏水膜”具有更好的压制性能。针对Cu50Fe50粉末,以无水乙醇作为PCA、球料比20∶1、转速300 r/min、球磨48 h的混合粉末具有更好的压制特性,压制得到的粉末压坯密度高达7.12 g/cm^(3)。