Burnishing Effect on Disc Brake Corrosion and Frictional Performance of Corroded Disk

Abstract

This work examined the frictional force induced by the disc brake when the disc brake gets corroded. The corrosion process was carried out on two types of disc brake labelled disc A and disc B where both disc brakes were made from gray cast iron but having different design. Both discs were burnished with two types of friction materials labelled P-1 and P-2 before they were exposed to the open air environment to simulate the disc corrosion for a parked vehicle. The change in brake torque and friction coefficient was analyzed using a single-end brake dynamometer. The results showed that the burnishing effect of the friction material has significant effect on the formation of oxide layer. Oxide layer formed on disc burnished with friction material P-2 was more concentrated and thicker compared to the disc burnished with friction material P-1. Also, the results showed that brake torque and friction coefficient were closely dependent on the removal of the oxide layer and by the friction film on the burnished disc surface while applying the brake. Thus the composition of friction materials is critical to affect the formation of the oxide layer on the disc and consequently, the performance of the frictional force of disc brake system.

Effect of manufacturing processes on the natural frequency, surface roughness and dimensional tolerances of GCI brake discs

“…Owing to their regenerative brake systems, EV brake rotors experience more rust because of insufficient heat generation and lack of use. Corroded brakes may cause squeaking or grinding noises that continue even after repeatedly applying brakes at greater speeds, eventually leading to brake failure [5][6][7][8][9].…”