Process Optimization of Automotive Brake Material in Dry Sliding Using Taguchi and ANOVA Techniques for Wear Control

Abstract

In this paper, an investigation of the load-dependent wear behavior of copper-free semi-metallic brake material is presented. The experiments were conducted in ambient thermal settings with varying sliding velocities (3.141 m/s, 2.09 m/s, and 1.047 m/s), normal load (60 N, 50 N, and 40 N), and sliding distance (4500 m, 3000 m, and 1500 m). Taguchi’s method was used in designing experiments to examine the output through an L9 orthogonal array. ANOVA was used to identify the consequence of interactions among different constraints. It also established the significant contribution of each process factor. The objective was set as the ‘smaller is better’ criterion to find minimum wear conditions. The impact of the normal load on the wear process was found to be maximum (71.02%), followed by sliding velocity (27.84%) and sliding distance (1.14%). The optimum condition for the minimum wear rate was found at 40 N normal load, 1500 m sliding distance, and 3.14 m/s sliding velocity. The results were confirmed with validatory friction experiment runs. The resulting error was within 10% error, which verified the experiment methods. The SEM investigation of worn surfaces of pin and disc confirmed abrasive wear and adhesive wear at 60 N and 40 N, respectively.

Dry Sliding Behaviour Study of Novel Low-metallic Friction Materials by using DoE-Taguchi Method

“…Results showed that wear rate is a function of load but decreases with an increase in speed. The percentage of reinforcement is also a major factor in the coefficient of friction (13,14). The dry sliding behavior of composite is studied by making specimen hand layup technique or compression molding method.…”

Optimizing Friction Block Location on Brake Pads for High-Speed Railway Vehicles Using Artificial Neural Networks

“…Harlapur [11] presented a relationship between the stopping distance of a vehicle and its brake pad thickness using simple machine learning algorithms. Saurabh [12] investigated the load-dependent wear behavior of copper-free semimetallic brake material. Through Taguchi's method and ANOVA, the impact of the normal load on the wear process was found to be maximum.…”