Wear analysis of eco-friendly non-asbestos friction-lining material applied in an automotive drum brake: Experimental and finite-element analysis

Abstract

Brake friction lining material is the critical element of a braking system, since it provides friction resistance to the rotating drum for controlling automobiles. The present study involves wear analysis of newly developed eco-friendly non-asbestos friction lining material for automotive drum brake applications using experimental study, finite-element analysis, and microstructural investigations. Theoretical interpretation of braking force at different automobile speeds was derived using fundamentals. Specimen drum brake liner with eco-friendly material compositions was produced using an industrial hot compression molding process at one of the manufacturer. The surface wear of the liner was measured using an effective and accurate method. Furthermore, a finite-element analysis model was developed considering actual operating conditions and various components of the drum brake system. The model was elaborated for various result outcomes, including Von-Mises stresses and total deformation of components of the drum brake, and further used to estimate the surface wear of the friction lining material in terms of transverse directional deformation. Finally, microstructural analysis of the friction lining material was carried out using scanning electron microscopy and energy dispersive spectroscopy. From the results, it is seen that the developed friction lining material is wear resistant. The finite-element analysis model can be effectively utilized to study the tribological characteristics of friction lining materials.

Overview of the Important Factors Influencing the Performance of Eco-Friendly Brake Pads

“…The coconut shell ( Figure 4 ) has better physical properties and a high compressive strength, which is dependent on the composition of the coconut shell. Based on these characteristics, coconut shell has the potential to be employed as a non-asbestos friction material for non-asbestos brake pads on a lightweight vehicle such as a motorcycle [ 32 , 33 ]. The effect of coconut shell powder on brake friction material was investigated by Daut et al The specimen is made of a mixture of aluminum oxide, maleic anhydride, epoxy resin, and coconut shell powder with different compositions.…”

“…From these results, it can be seen that the FLM developed using coconut shell powder has good wear resistance. The tribological characteristics of friction lining materials can be studied effectively using the finite-element analysis model [ 33 ].…”

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

“…Furthermore, there has been much research in the past on the optimization of the brake manufacturing process. However, insights into the wear process, factors affecting it, and the interaction among the wear process variables are still needed [13][14][15][16][17][18][19][20].…”

“…Furthermore, there has been much research in the past on the optimization of the brake manufacturing process. However, insights into the wear process, factors affecting it, and the interaction among the wear process variables are still needed [13][14][15][16][17][18][19][20]. Because of the complexity of the wear process, a scientific methodology is required to investigate the tribological properties of the friction pair.…”