Abstract
This study deals with the development of drum brake liner for a multi-utility vehicle possessing a hydraulic brake system by varying 7 weight % of steel fiber and stainless steel fiber each, in friction composite formulations. The developed friction composites were tested for physical, chemical, corrosion, mechanical, thermal properties, and tribological characteristics, under near-actual conditions using an inertia dynamometer as per industrial standards. Finite element analysis software (ANSYS) analysis was performed to show the thermal stress distribution of the developed friction composites at the maximum temperature rise due to heat generated during brake stops, and an extensive evaluation method was used to rank the composites. The study concludes that the brake factor of the stainless steel fiber-based friction composite produces stable performance in all conditions with a lower liner temperature rise of 340 °C and lower thermal stress at 4.255294 MPa. However, the steel fiber-based composites produced high performance at the beginning but deteriorated after a certain period due to higher levels of corrosion and a high temperature rise of 361 °C resulting in a negative fade (−0.84%) and more thermal stress (5.619102 MPa). The primary plateau, secondary plateau, back transfer of drum wear debris, and the distribution of constituents on the worn surface of the developed composites in a resin matrix were identified and studied using a scanning electron microscope (SEM) equipped with energy-dispersive spectroscopy.
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Acknowledgements
Authors express their gratitudes to Mr. Samit Singhai, Kasturi Metal Composites Private Limited, Amravati, Maharashtra, India, for providing the steel and stainless fibers. Authors also thank the well-wisher(s) who have helped in manufacturing and testing of these friction composites.
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D. Lenin SINGARAVELU. He is working as an associate professor in the Department of Production Engineering, National Institute of Technology Tiruchirappalli, Tamil Nadu, India. He obtained his Ph.D. in the field of friction materials in Metallurgical and Materials Engineering Department from IIT Roorkee. He holds an Indian patent in his name in the field of brake friction materials. He has 14 years of research experience and 10 years of teaching experience. His areas of expertise are friction materials, tribology, powder metallurgy, natural fiber composites, processing of polymer products, nonconventional machining, composites processing, and shape memory alloys.
R. JAYAGANTHAN. He is working as a professor in the Department of Engineering Design, Indian Institute of Technology, Madras Tamil Nadu, India. He obtained his Ph.D. in the field of materials engineering from IISC Bangalore, India in 1998. He had been awarded Alexander Von Humboldt Fellowship by AVH Foundation, Germany in 1998. He has six years of post-doctoral research experience at Max Planck Institute for Metals Research, Stuttgart, Germany, and National University of Singapore. His area of research includes additive manufacturing, Severe Plastic Deformation (SPD) processing, fatigue & fracture mechanics, structure-property correlation, structural nanomaterials, and Finite Element Modeling (FEM) simulation.
Vijay R. He is currently pursuing Ph.D. in the field of brake friction materials from Department of Production Engineering, National Institute of Technology, Tiruchirappalli, Tamil Nadu, India. He completed his bachelor in mechanical engineering in 2012 and master in computer integrated manufacturing in 2014 from Anna University, Chennai, India. His area of interest includes brake friction materials, natural fiber composites, and tribology.
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Vijay, R., Singaravelu, D.L. & Jayaganthan, R. Development and characterization of stainless steel fiber-based copper-free brake liner formulation: A positive solution for steel fiber replacement. Friction 8, 396–420 (2020). https://doi.org/10.1007/s40544-019-0280-8
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DOI: https://doi.org/10.1007/s40544-019-0280-8