Search Results

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 entering 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 exhaust emissions, there is still concern regarding non-exhaust emission, such as brake dust, which can potentially cause harm to human health and the environment. Despite EVs primarily using regenerative braking, they still require friction brakes as a backup as and when required. Moreover, most EVs continue to use the traditional grey cast iron (GCI) brake rotor, which is heavy and prone to corrosion, potentially exacerbating brake wear emissions.

Aluminium alloys have been used extensively in the automotive industry to reduce the weight of a vehicle and improve fuel consumption which in turn leads to a reduction in engine emissions. The main aim of the current study is to replace the conventional cast iron rotor material with a lightweight alternative such as coated aluminium alloy. The main challenge has been to meet both the cost and functional demands of modern mass-produced automotive braking systems. A sensitivity analysis based on the Taguchi approach was carried out to investigate the effect of various parameters on the thermal performance of a typical candidate disc brake. Wrought aluminium disc brake rotors coated with alumina on the rubbing surfaces were determined to have the best potential for replacing the conventional cast iron rotor at reasonable cost. Optimisation of the structure was subsequently carried out using a genetic algorithm on the selected coated aluminium disc brake rotor.

Disc brake squeal can be classified as a form of friction-induced vibration. The elimination of brake squeal noise is very important as the problem causes discomfort of the vehicle occupant as well as pedestrians. This paper presents a new methodology for predicting disc brake squeal using finite element analysis considering both thermal effects and the structural compliance of brake components. An integrated dynamic study of non-linear contact pressure analysis and a fully coupled transient thermal analysis under variation of contact algorithm are performed before executing the instability study of a typical passenger car brake system using the complex eigenvalue analysis method. Based on the results of this exercise, a parametric study on the materials of brake components is carried out to define suitable design guidelines to reduce or to eliminate squeal problems.

This paper reports the results of a back-to-back comparison of the squeal and judder propensity of simple cast iron and siliconised carbon disk brake systems. A finite element simulation approach is used to predict the squeal propensity of the two systems based on the results of a complex eigenvalue analysis. These results which are validated by dynamometer noise tests carried out according to the SAE J2521 [1] standard procedure show that the siliconised carbon rotor is much less prone to squeal over the range of conditions considered. The combined experimental and numerical simulation approach is also applied to the problem of hot judder for the two rotors. The critical rotational speeds for hot spots to form are predicted to be an order of magnitude higher for the siliconised carbon rotor system. These results demonstrate the potential of the new carbon composite rotor material to reduce the occurrence of noise and vibration problems in automotive brakes.

A non-linear contact analysis of a leading-trailing shoe drum brake, using the finite element method, is presented. The FE model accurately captures both the static and pseudo-dynamic behaviour at the friction interface. Flexible-to-flexible contact surfaces with elastic friction capabilities are used to determine the pressure distribution. Static contact conditions are established by initially pressing the shoes against the drum. This first load step is followed by a gradual increase of applied rotation to the drum in order to define the maximum reacted braking torque and pseudo-dynamic pressure distribution at the transition point between sticking and sliding motion. The method clearly illustrates the changes in contact force that take place as a function of the applied pressure, coefficient of friction and initial gap between lining and rotor. These changes in contact area are shown to influence the overall stability and therefore squeal propensity of the brake assembly.

Important constituents contained within modern friction materials include a variety of particles, fibres and fillers (collectively termed “inclusions”) that are added to give desired frictional characteristics to the baseline matrix material. The proposed paper presents the results of a microscopy study which has utilised image enhancement software to measure and evaluate the raw constituents of a typical friction material in terms of size, shape and aspect ratio of inclusions. This characterisation has been extended to determine the statistical distribution of constituent inclusions over the working interface after pad manufacture, as well as to measure the degree of inclusion exposure above the free surface. Experimental tests on the binder system (matrix material plus matrix fillers) have also been undertaken to characterise the thermo-mechanical properties at ambient and elevated temperature.