Upload
others
View
2
Download
0
Embed Size (px)
Citation preview
ZOOB-O1-z5B1
eSquealReduction
byNamtechnologyAStudyonFrictionMaterialshrBrake
MasaakiNishiwakiandKenjiAbeToyotaMotorCorp.
HiromichiYanagiharaandIgorStankovicToyotaMotorEuropeNⅥSAR&,.
YujiNagasawaToyotaCentraIR&DLabs・Inc.
SatoshiWakamatsu
ADVICSCo.,Ltd.
Copyright◎2008SAEIntemationaI
causedbydynamicinstabilityofthevibrationsystemcomposedofdiscbrake,knuckIeandsuspension,ThisisanalyzedbyflutterofthevibrationsystemundersmaI1disturbanceoffrictionfOrcevariation,whichisshownin
references[4]and[51Recently,FEAnalysisofbrakesqueal[6]isappliedfOrbrakedesignrefinementsfO「brakesqueaIreduction、ButitwilIbesometimesdifficulttomodifythevibrationsystemfOrdynamicstabilityinallvibrationmodes・ThenitwiIIbemoreimportanttoreducebrakefrictionforcevariation、ThispapershowstheconceptofpadmaterialsdesignfOrhigherperfOnnanceandIessbrakesqueaLwhichisbasedontheMDsimuIationandexperimentresults.
ABSTRACT
Brakesquealiscausedbydynamicinstability,whichisinfluencedbyitsdynamicunstablestructureandsmalldisturbanceoffrictionfOrcevariation、RecentIy,FE
AnaIysisofb「akesqueaIisappIiedfOrbrakedesignrefinements,whichisbasedondynamicinstabiIitytheo「y・AssameastherefinementofbrakestructureisrequiredfOrbrakesquealreduction,therefinementofpadmaterialsisalsorequiredfOrbrakeeffectivenessandbrakesqueaIreduction・ItiswelIknownthatfrictionfiIm,whichiscomposedofpolymerslikephenolfOrmaldehyderesinandsoon,innuencesfOrfrictioncoefficient・TherefOreitisexpectedthattherefinement
ofpoIymersinpadmaterialsenablehigherbrakeeffectivenessandlessbrakesqueaLlnthispaper,MoIecuIarDynamicsisappliedfOrthefrictionfOrCevariationofpolymersinpadmateriaIs・TheMDsimuIationresultssuggestthereductionmethodoffrictionfOrcevariationofpoIymers・TherefinementofpadmateriaIsisshownherebasedontheMDsimuIationresuIts,whichisassuredbyexperiments・ThispapershowsthepossibiIityoffrictionmaterialsdesignwithhigherperfOnnanceandIessbrakesqueaL
INFLUENCESOFFRICTIONSURFACE
Padmaterialsarecomposedofmetalfiberprganicfiber,
inorganicfiber,barite,otheradditives,graphite,phenolfOnnaldehyderesinbinderandorganicfiber[71TablelshowsthetypicalfOrmuIationoffrictionmaterials.
TblbleLTypicalFbmnllationofFtictiomlVhtaials
(四m) @m) ‐・氏ロ亡(℃篝
INTRODUCTION
Recently,higherbrakeperfOrmanceincludingbrakeeffectivenessisrequiredfOrvehiclesafetyAtthesametime,brakesqueaIreductionisaIsorequiredfOrcomfOrt
ItisweIIknownthatpadmaterialsofhigherfrictioncoefficientsometimescausebrakesquealgeneration、Brakenoisereductiontechnologydevelopment[ncomestobemoreimportant,becausebrakesqueaIismuchinfIuencedbyfrictioncoefmcientofpadmaterialswhichisshowninreferences[2]and[31Brakesquealis
*dBcdTpodUm
Figurelshowsthefrictionsurfacebetweenpadanddisc・FrictionfOrcedependsontheabrasiveandadhesivefrictionmechanismsBrakedisciscomposed
2008年10月7曰9時10分1158618
Mpb臼遡 0画ncdFbmUa VOL% 、■T唾e「(似、) 、■ごM9㎡) Ⅱ侭th屯ppb化GQ
M試凶F鼬b画 FEO4etG 10 <のzDOx3000 7~9 >1000
Q画icFもb官 A宙T洞R」p 10 ~d10x3000 1.4 >500$てり
h面寧UCF西be「 Ⅱ附画乱G=s 10 <の10x30DO ~4 ~1000
b面戸icli順「 Mner凶,G蚕s 10 <200 へ剣 ~1000
B曰nhD BBSq 20 ~10 45 1580
Oけ画addHh型= S」5dBCa(dJ2 5 <200 へq ?。
Cレヨオfte C 5 <5pO 23 へる400
0画icRi臼 C館。■w、」5t 10 ~500 1.1 300へ60Ⅸ#①
F1直域彪R巳載、 (cVtodtqh 20 ?。 13 300~600②[,
Figure3showsthemonomermodelofbeadswithmassesandsprings,AlsoFigure3showsthepolymermodelofanumberofchemicalUnitsincoarse-grained
model、ArealpoIymerisassumedbasedonthemodelshowninreference[101A、ymeasurablequantityQwithadimension[Q]specifiedinS1unitskgmands,ismadedimensionlessbyareferencequantityQrefinequation(1)for[qinequation(2).
ofcastiron,Throughoutbrakeburnish,friCtionfilmsincIUdingphenolfOrmaldehyderesinaretransferredfrombrakepadstodiscsurfaces,1tiswelIknownthatfrictionCoefficient〃isinfluencedbyfrictionfiImsshowninFigure2,whichisshowninreferences[8]and[g1ThefrictionfOrcevariationwillbeabletoreducewiththe
refinementofpolymerslikephenolfOrmaIdehyderesin、Inthispaper,thehigherfrictioncoefficientpadmateriaIisappliedfOrthisexperiment,whichincIudeIow-steelfiberand0.1%SiCabrasive,ThehigherstiffnessandlessdampingpadmateIPialisappIiedfOrthisexperiment,whichisremovedofcashewdusts・Thebinderofpad
materiaIsisreplacedofphenoIfOrmaldehyderesintootherpoIymers.
mα+β/2rOβ+γごγ/2
kgαmβSγ
QdimlessQref
(1)
(2)
(3)一一一一一一
《]守口』
配句I■■■l
ol-pol-
ThepolymerchainlengthfOrIinearity,thepersistenceIengthIpdetenninedbythechemicalcharacteristics,isgivenbyequation(4).ThepolymerscometogetentangledfOrlongerthanIpOntheotherhand,theequationlp=Orepresentsnobendingstiffness.
価テビビ珂厨園、E団画………①竺壁21222ヅ
(4)1p=aに。。+1)/2
wherea:UnitIengthshowninFigure3[10]C、。:FIoIPy,scoefficient■■■
FigureLFrictionSurfaces Table2showstheQreferencevaIuesofPoly-Tetra-
F1uoro-EthylenePTFEThereferencemassiscaIculatedbytheequationm=mb(1p/lp*)/(Avogadroconstant).UnitmassstandardpolymerFENEmodelisshowninTabIe4whichisderivedfromPTFEreferencevalues・ThereferencevaIuealength,energyandsoonarecalculatedbytheequationsshowninTable3.
I11q①巳-■
4.1壼
1」
5.
町- 1
I Ⅲ
!! 』
李一
]po-o垣弔の。Qロ。}]o垣四 鰯
Table2.PTFEReferenceValues
β7FEreにTencevBIuB
hy
孵卵岼蠅疵》
〔)|弓
Ⅱ:;う|()7511Nド
RatioofFrictionFilmArea(%)
Figure21nfluenceofFrictionFilms[9]
REDUCTlONOFFRICTIONFORCEVARlATION
INPOLYMERSEblc3.M匂moeMdues
MODELOFPOLYMERS
Itisknownthatthechemicalconstituentsdetenninethe
factorsinmaterialbehaviorofmacroscopicsystems.
MDaekBisBOIlmEnnco【BtmtalXlTInisndhngtalpeIBmeinKelvin
鰹, ̄露 Table4PolymerData
二二> PTFEPAIFENEmoc
ヴw22a,1k〕`CQ
Figure3・ModelsofMonomerandPolymerUO]
2008年10月7日9時10分1158618
I〕]
1r ̄
烏`.
コーーーーー-百F--
.,_誤註、-~尾
イー、%…!「可
:笈き;
Lq
G才蟻rfI9.
3.
i8h
|§;
鷺
!
_』
露 αβγ PTFEre化rencev llue αβγ PTFE唾lbTencevalue
m2S里
lenglh
time
energy
lbrce
stress
lOO
OIO
OOl
l2-2
11‐2
1-1-2
1.28×lO-zjk
1.44×10‐
477×10‐
,
11
1.17×10.z0
8.13×10.12
3.,2×106
9
、
S
』
N
Pa
shearTate
viscosity
tempemture
sur値cenumberdensity
buIkmassdensity
buIknumberdensity
00-1
I-l-l
l2-Z
O-ZO
I-3O
O‐30
2.lx10
1.9xlO
10
弓
Hz
Pas
847.5K
4800 A-z
4.3 9/c、
3300A・〕
〕
Lerロh 11』畷。 T百Tpa旨hJe B旧[bノ RessIe T1「TB 雷:
n.=Ib
=IR/1P*
、甘=Ibj T菌=Trn而捗 》
蝿
閑=E3
=n画eh面
腱=
「b(meud)l/2
一》γ
崎
PoIymer FENEmodcI PTFE PAI
PersistencelengthIp(IC。、ml 1.34 19.3 35.0
MonomerweightmbIg/moll 6Z6.Z 190
Bondlengtha(10.9mI 0.97 1.55 4.0
Cha『acteristicratio C 。。1.76 Z4.0 16.5
CriticaIweightN値 100 21
MeltingtemperatureT 、 (K) 0.7 593 548
caIcuIationresultThedynamicbehaviorofmonomerispredictedbytheiterationofcalculation、ThefrictioncoefficientMsadimensionlessquantitywhichwon'tbe
infIuencedbyintermoIecularchemistry,TherefOreonepoIymerisassumedbymuItibeadsspnngmodelwithNcbeadsinthiscaIculationwhenFENEmodeIhasNc=100
beads、Figure5showstheeffectofagingfOreasyunderstandingWhentheactuaIcontactareaisvariedsoquickIy,frictionfOrceisaIsovariedsoquickIyAccordingIy,frictionfOrcevariationisinfluencedbyagingtimecoefficientDandreIaxationtimecoefficientて.
FrictionfOrCevariationwillbereducedbythe
refinementsofparametersDandて.Figure6showsthe
poIymermodelundershearfOrce・ltwiIlbeabletoconsiderthereductionofstressconcentrationbytherefinementofpoIymeranditscharacteristics・
理ingp『Bventaging
ThereferencevaluescanbecalcuIatedbyequation(1).Thenthestressofnormaldirectionandshearstressin
frictionsurfacecanbecalculatedinequations(1),(2)and(3).Frictioncoefficientisgivenbytheratioofnormalandshearstresses.
DYNAMICBEHAVIOROFPOLYMERS
Equation(5)givesthemotionofmassmofbead,whichisinfIuencedbythepotentialUbondcomposedofLeonard-JonespotentialULJandFENEmodelpotentialUFENE-cshowninFigure4、BasedontheMoIecular
l1II1i薦iillii肇鵬蝋舅篭騨驚equation(5)representsviscous-elasticcharacteristicsofpoIymers.AIIentriesfOrreaIpoIymershavebeenestimatedfromthereference[11LThefOrcerepresentsthevariatio、frominitialvalueFintthroughoutmaxvalueFmaxtothefinaIstablevaIue.
-=ザ「…鋭一
邉霞$:三二二二膣二二jiLl豊科~.▲‘
DP
t=0
↓、。-」
+ +
t=△t
GreaterVariation Reduced
.〒了‘α08_
」u’1A)’t1I鈩人ムャヌナチ.、.‘--1ttlL■庁
Figures・FrictionForceVariationinPolymers
Shear-->
ぴ'(M=Ujムノ÷ぴ画雌◎
Figure4FENEPotential
Mx=ks(VSt-x)一万(X)xA-Emx-(Fint戸Rmx)(1ィの(0/r)
(5)●●
の=1→【の,
< ̄Entangled
Defbrmation
t=0whereM:Monomerweight
x:Displacement
ks:SpringstiffnessDerivativeofPotentialFunctioninFigure4
vs:Sheerrate
t::time
刀:DampingfactorA:Area
Fint:lnitialvaIueofextemalfOrce
Fmx:MaximumvaIueofexternalfOrce
D:Agingtimecoefficientて:Relaxationtimecoefficient
旦、、/t=△t
Figure6PolymersModelunderShearForce
ThefrictionfOrcevariationbecomesmaIIerinthe
poIymerwithstraightchainstypestructurelikePoIy‐Amid-1midesPAIthanthepoIymerwith3-DimensionaIchainstypestructurelikePhenolfOrmaldehyderesin、lncaseofthePhenolfOrmaldehyderesin,doubIebondispresentedbythechemicalstructurethatgiveshigherfrictioncoefficientanditsvariations、ItspoIymerchainsstructurecanstoreamountofpotentialenergyandits
ThespeedofvariationisdeterminedbyagingtimecoefficientDandrelaxationtimecoefficientて.Thenthe
frictionfOrcevariationcanbecalculated・Nextstepofthedynamicbehaviorofmonomeriscalculatedbythelast
2008年10月7日9時10分1158618
Equation(7)isgivenbytheratiobetweenviscousshearfOrceandpolymerdiffusionfOrceWhenthediffUsionconstantDisverysmallthroughinterfacebetweendiscandpad,Equation(7)hasthevalueclosetoconstant.
poIymerchainsstructuresuddenIyreleaseitsenergyafteryieIdstress、ThengreaterlocalvariationoftheshearstressandthenormaIstresscausethegreater
variationoffrictioncoefficient[141
….71…_、uIl
if-識T-←、_●●・[.
戸厚.、(j,ド).・鴛
託:苫…'>』:`今~へ;:…'巖\‐γい・
灘割宅ご声瀞; ̄グー ー出音・-率 ̄ず、~≧~ ̄
…(…;「f:}…-j亀ノーレ…'一、診,?』
>・、--『.・・T
3-DimensionalchainstypeStraightchains
Figure7.MolecularStructures[13]
CONSIDERATlONOFDYNAMICS
山一(叶哨 (7)
whe「ev:VeIocity
L.:Polymerlayerthickness
T:Temperature
kB:BoltzmannconstantD:DiffUsionconstant
Equation(8)isgivenbytheentanglementofpoIymerlengthNbidsandFENEspringrigidityconstantskFENE[14LHerePTFEreferencelengthlrefiscalculatedbytheequationlref=[kB(Tm/Tm)/(yieldstress)]'/3.1ntheyieldstress100MpaofPTFE,I『ef=4.9/101o[m]iscalculated・ThenNumberofFENEPolymerfOr
persistencelengthNbids-lp=19.3/4.9iscaIculated.
Thefrictioncanbeunderstoodasaprocessoftransfer
oftheenergyfromtranslationintonormalmotionofatoms・Frictioncoefficient科dependsontheequations
(6),(7)and(8)showninreferences[14][15lTheseequationsarederivedfromeachconsiderationofrelationshipbetweenmacroscopicandmicroscopicviewpoints・Figure8showsthepolymermodellocatedwiththeangIesaandβtofrictionsurface・TheangIeagivesthedistancedo・Hereα=βisassumedfOrthedependenceonsurfacedensitMbeadsize,andpolymerthicknessinthismodeI,ConstantAisintroducedto
includethefactthatnon-zerofrictionexists,alsowhen
surfacedensityislargeandbeadsareverysmalLEquation(6)isgivenbytheangleainpolymerfrictionsurfaceandgeometricfactorsrbid,dsumdoandβof
1
(8)U3
q厨
q|脇
Constant
Constant
lp/|p*PersistenceLengthofFENEmodel
SpringRigidityofFENEmodeI
whereCN:
Ck:
Nbids=
|p*:
kFENEI
polymermodelshowninFigure8.
』i三≦二京FぐNext,caIculationresultsoffrictioncoefficientbasedontheequations(8)areshowninFigure9andFigurelOParameterstudywasmadeinNbids-lp=4andkFENE=30.FENEspringrigidityconstantkFENE=30isassumedbythemediumvalueofthegeneralrangeofkFENE=5-60.Nbids-lp=4representsFENEmodelofPTFE,whichrepresentthestandardsizefOrmodelingPoIymerdenSityNchainiSgiVenbyNchain=8/rmon,WheremOnOmerthicknessmeasureddatadividedbyFENEIengthrmon=
5/4.9.Figure9showsthefrictionCoefficient似infIuencedbypolymerdensityNchainandNumberofFENEPo1ymerfOrpersistencelengthNbids-lplnshorterNbids-Ip,メノbecomeunstablewiththevariationof
polymerdensityNchain、InIongerNbids-Ip,似becomestablefOrthevariationofpolymerdensityNchain・Figure9
showstheregionsuitablefOrhigherfrictioncoefficientluandreducingitsvariatiomwhichincludesPoIy-Amid-lmidesPAl,Poly-1midesP1andPoly-EtherEther-KetonePEEKFigu「elOshowsthatthefrictionCoefficient似isinfluencedbypolymerdensityN-chainandFENEspringrigidityconstantkFENE,InlesskFENE,ノLLbecomeunstabIewiththevariationofpo1ymerdensityNchain・lngreater
kFENE,lLLbecomestabIewiththevariationofpoIyme「
densityNchain、FigurelOshowstheregionsuitableforhigherfrictioncoefficient」uandreducingitsvariation,whichincludesPALThisregionprovidesthereductionof
Ⅱロ
R一斤
一一
】pH
where
Zrbid:DiameterofBead
dsurf,do:DistancebetweenEachBead
:AngleinPolymerandFrictionSurfaceα
β:AnglcinForceworkedtoMonomers
Figure8PolymersModelinMolecularDynamics
2-塾一十Aαs"ぴ
ul (6)
〃「」
whereA:Constant
2008年10月7日9時10分1158618
frictioncoefficient似variationinhighertemperatureoffrictionsurface.. 一雨
h画すⅡsc1HMicnc2HIsedby
露 DSmmlゾノOIne
50
11
52
。}‐寅畳z二勧皀③]の。巨巴四場』⑪凸
凹&5E身。」四z四四』。』質岩屋。Z
911霧爾
一噂」
つM⑥SqjealGbnaHdcnⅢH1
75
NumberofChainsN‐chain
Figure9・FrictionCoefYicient似inHuencedbyNbids-lpandN-chainロ税9$侭P「得390戸
!【5Gt!VibmtimModeofm沼keSqPeal!【5Gt!・
Figurell、BrakeSqueaIMechanism.
4
面『z里]曽田晋oQm皀渭二四四z四四
EXPERlMENTSOFBRAKESQUEAL
Thevariationoffrictioncoefficient似isreducedbythe
repIacementofthe3-DimensionalchainstypestructureIikePhenoIfOrmaldehyderesintotheotherpoIymersWithstraightchainstypestructureIikePAl、PIandPEEKTheseconSiderationsbasedonthecaIculationresults
showninFigure9andFigurelOwereexaminedbysomeexperimentsoftestpeacesandfuIIsizediscbrake.
NumberofChainsN‐chain
FigurelOFrictionCoefficientLLinfluencedbyKFENEandN-bidsFRICTIONCOEFFlCIENTOFTESTPlECES
Figurel2showsthefrictioncoefficientmeasurementoftestpeaces[161ThisequipmentisfOrの50×t5discin
castiron,padmateriallO×10mmpolymersoractuaIbrakepadmaterialsThetestpeaceispushedagainstthediscbyaircyIindercontroIledbyloadcelI.
Basedontheseconsiderations,thehigherandstabIe
frictionCoefficient/L「equiresthreecharacteristics,
polymerchainsdensityNchain>6,NumberofFENEPolymerfOrpersistenceIengthNbids-lp>6,FENEspringrigidityconstantskFENE>50.
=i妻'二BRAKESQUEALMECHANISM
TestPi
Thedynamicinstabilitytheory[5]describesthatflutteriscausedbydynamicunstablestructureofitsvibrationsystemanditssmalldisturbance、Thevariationoffrictioncoefficientuinpolymerwasstudied,Theconsideration
ofbrakesquealmechanismisshowninFigurell、Thevariationoffrictioncoefficient〃iscausedbyagingof
poIymers,whichisexplainedinFigure5・FrictionfOrcevariationbetweenpadanddisccausesthebendingmomentvariationofdiscshowninFigure11.Whenitsvibrationmodeisdynamicu、stable,BrakesquealwillbecausedbynuttermechanismlikecoupledvibrationofaircraftwingsBasedontheseconsiderations,thehigherandstablefrictionCoefficient似isprovidedbythe
suitablepoIymersintherequiredregionsinFigure9andFigurelO・ThepolymersaresuitablefOrthepadmaterialsinhigherfrictioncoefficientandlessfrictionfOrCevariationfOrreducingbrakesqueaI.
D×1m
der
ご(鍾雲)|鰯ミミニーニつ、is
の50
劇Be
Figurel2FrictionCoefficientMeasurementofTestPiece
2008年10月7日9時10分1158618
TESTPIECESOFPROTOTYPEMATERIALSFrictionfOrceismeasuredbystraingages、ThenthefrictioncoefficientiscaIcuIatedbyfrictionfOrce,normalIoadanditsgeometry・Burnishwasdoneundertheconditions,normalload200Nvelocitylm/s,
temperature75℃or150℃andlhourAfterburnish,thefrictioncoefficientwasmeasuredunderthecondition,
normalIoadlOONor200N,velocitylm/s→O→1m/s,
temperature75℃or150℃.
ThehigherfrictioncoefficientpadmaterialwasappliedfOrthisexperiment,whichincludelow-steelfibberand0.1%SiCabrasiveThehigherstiffnessandlessdampingfactorpadmaterialwasappliedfOrthisexperiment,whichwasremovedofcashewdusts、AndthebinderofpadmaterialswasrepIacedofPhenolfOrmaIdehyderesintoPALFigurel4showsthefrictioncoefficientinpadtemperaturel50℃influencedbysIidingvelocityinConventionaIpadmaterialsusingPhenolfOrmaldehyderesinbinderandprototypepadmateriaIsusingPA1binder.
TESTPIECESOFPOLYMERS
ItispredictedbycalcuIationresultshowninFigure9thatthefrictio、CoefficientメLisstableinPAI,PlandPEEK、
Figurel3showstheexperimentalresuIts・ThesegraphsshowthefrictioncoefficientuinfluencedbysIiding
veIocityinPhenolfbrmaIdehyderesin,PAlandPEEKTheleftgraphsarefOrthepadtemperature75℃、Andtherightgraphsarefbrthepadtemperaturel50℃・ltisshownthatthefrictioncoefficientluofPhenol
fOrmaIdehyderesinisunstable,especiaIIyin150℃・Ontheotherhand,thefrictioncoefficient〃ofPA1isstable・
Itisshownthatthefrictioncoefficient-luofPEEKis
stablein75℃,butunstabIein150℃.FigurelOshowstheinfluenceofFENEspringrigidityconstantkFENE,It
representsthatthefrictionCoefficient似isinfluencedbyFENEspringrigidityconstantkFENE,whichrepresentsthecapacityfOrtheinfluenceoffrictionsurfacetemperature・ThefrictioncoefficientlLLisstableinhigherFENEspringrigidityconstantkFENE.
1叩叩叩皿0
ユニ宮のちP車の。Q自。一己垣』
叩叱四匹0
1首⑪一○鱈①oQg冒逼
詞翰塞匪
005o05
Vblocity(m/s)Velocity(m/s)
(a)PhenoMbrmaldehydclesmBinder(b)EAIBinder
Figurel4FrictionCoefficientsofPrototypeMaterials
Theaverageαisalmostsame,Thenegativeslopeoffrictioncoefficientversusslidingvelocityisalittlebitdifferent・ltwillbeabIetopredictbrakeeffectiveness・ButitwillbedifficulttopredictbrakesquealgenerationbasedonthedatainFigurel41tispossibletopredictbrakesquealgenerationbasedonthedatainFigurel3.
TEmp150℃Tbmp、75℃
186420
・0000
二]目⑪己』軍⑪CQ臣◎垣○一』』
1日6420
0000
ユ旨⑪一○鰻}②。。臣◎一》○疸四
iiHZ寵iimiimiiM3 BRAKENOlSETEST
BrakesquealevaluationtestsweredonebyfullsizefIoatingcaliperfrontdiscbrakesystemfOrpassenge「car・Thisdiscbrakehasの57pistonincylinderoffloating
typecaliperandの255×22mm・ventilatedtypebrakediscmadeofcastiron,Anti-squealshimswereremovedfOrduplicationofbrakesquealtest・Figurel5andFigurel6showthedynamometerbrakesquealtestresults,BefOrebrakesquealtests,1000timesbrakestopsweredonefOrbrakeburnish,whichwasconStructedofinitial
vehiclevelocity<50km/h,padtemperature<150℃,desecration<029.AfterlOOOtimesbrakebumish,500timesstopsweredonefOrbrakesqueaIevaIuationtest,whichwasconstructedofthesamekindsofbraking
condition・Figurel5showsthecomparisonoftherateofbrakesquealgeneration・TheIeftgraph,fOrtheconventionaIpadmateriaIusingPhenoIfOrmaldehyderesinbinder,showstherateofbrakesquea182%in500timesbrakingTherightgraph,fOrtheprototypepadmaterialusingPA1binder,showstherateofbrakesqueal40%in500timesbraking・Thefrictioncoefficientisalsomeasuredinthisbrakesquealtest、Theaveragevalueoffrictioncoefficientisalmostsame処=0.42.You
canseetheeffectofthereplacementofPAIbinder.
--!
VeIoc師(m/s)O VCloc艀(m/s)O
(a)Phenolfbrmaldehyderesin
i86420
nUnUnJnJ
二旨⑭一○塵』⑭oQEo-】○恒』
・86420
0000
1首②一○垣⑭。。■。}]ロ恒』
OO5
Velocity(m/s)
0.5
Velocity(m/s)
0
(b)PAI
086420
0000
1】臣⑪一。唱⑧CQEo室○一』」
・86420
0000
-]臣⑭-9糧⑪CO臣。|】g巨」
題3111鰹&~山車 ̄=扇雪琿睡國辱罹
V亀,、綿(m/圏)0 00.5
Velocity(m/s)
(c)PEEK
Figurel3FrictionCoefficientofPoIymerTestPeaces
2008年10月7日9時10分1158618
懸蝕■軍ロ毎■■■==ヰー
「 。
E二二二二
|=1-i
▲
戸一一一一一一一亟訶■電
Imi
●
(3)ThehigherfrictioncoefficienMandthereductionof
itsvariationcanbeprovidedbythethreesuitabIecharacteristics,poIymerchainsdensiIyNchain>6,NumberofFENEPolymerfOrpersistencelengthNbids-1p〉6,FENEspringrigidityconstantskFENE>50.TherefinedpadmaterialproductswilIbedevelopedafterotherrequirementsstudies,fade,wear,andsoon.
伽l(ま)。 82%
葛肩⑨ヨゥのc畢飼』国
4096
,u=0.42 似=0.42
0
(a)Phenolfbmlaldehyde1℃sinBinder(b)PAIBinderREFERENCES
Figurel5、RatioofBrakeSqueaIGeneration 1.M.Nishiwaki,‘`Reviewofstudyonbrakesqueal",
JapanSocietyofAutomobiIeEngineeringReview,11(4),p48-54(1990).
2.N.Millner,“AnAnaIysisofDiscBrakeSqueaI,,,SAEPaper,780332(1978)
3.M.EriksonandS・Jacobsen,,,Frictionbehaviorand
squealgenerationofdiscbrakeatlowspeed,Proc・
lnstn、Mech,Engrs.,PartD,JournalofAutomobiIeEngineering,pl245-1256(2001)
4.M.Nishiwaki,“GeneralizedTheoryofBrakeNoise",
Proc,Inst、MechEngrs.,JoumaIofAutomobileEngineering,VOL207,PartD,pl95-202(1993).
5.V、VBolotin,‘‘NonconservativeProbIemsofthe
TheoryofElasticStabiIity",PergamonPress,p7-9
(1963).6.G.DLiles,,,AnaIysisofDiscBrakeSquealUsingFinite
ElementMethods,,,SAEPaper,891150(1989).7.Y・SasakiandSKusaka,”TheTransitionof
AutomotiveBrakeLiningMateriaIs",JoumaIof
JapaneseSocietyofTriboIogists,Vol、41,N0.4,
pl97-201(2003)8.s.KRhee,M、G・JackoandH.S・Tsang,,,Theroleof
frictionfilminfrictio、,wearandnoiseofautomobile
brakes,,,SAEPaperNo900004(1990)、9.N、Odani,MKobayashiandK,Kakihara,轍Effectof
TransferredSurfaceFilmon似BehaviorofDisc
BrakePadinHumidityEnvironment",SAEPaperNo、
1991-01-3391(1991).
10.H,YanagiharaandM,Kroeger,,'Polymermaterial
designmethodanddesignsystem,',JapanPatentApplicationNumber2005-163662(2005).
11.RoSPorterandJ・F・Johnson,Chem、Rev、66,
1(1966);J,BrandrupandEH,Immergut(eds),
象|酸li19;:flbookoWiloy-ln…ien・aNewYo『k'12.M.Kroeger,“SimpIemodelsfOrcomplexnon
equilibriumfluids,,,PhysicsReportsp453-551(2004)13.WikipediathefreeencycIopedia,“Phenol
fOrmaldehyderesin",http:"enwikipediao「g/Wiki/Phenol
l4MNishiwaki,HYanagihara,Y,FUjioka,KAbeandHIsono,`DesignmethodoffrictionmateriaIswithnonoise,,,Patentpending
15.J・Kim,“Atomic-scaIeoriginsoffrictio、''’1angmuir,12,p4564-4566(1996).
16.Y・Nagasawa,K・Yoshida,MHashimotoand
MNishiwaki,‘`Frictiontestpiecetester,Japan,PatentApplicationNumber2004-12172(2004).
Figurel6showsthecomparisonofthebrakesqueaIfrequencyandsoundpressureleveLWhenbrakesquealoccur,itspeakofsoundpressureandsqueaIfrequencyanaIyzedbyFFTwaspIottedinFigurelaTheleftgraphisfOrtheconventionalpadmateriaLandtherightgraphisfOrtheprototypepadmateriaLThesoundpressureIevelisreduced20dBlower・ThenbrakesquealwasaImostdisappeare。.
釦、印印
11
(四℃)一。シ⑪曰のご腸巴凸己皀二○m
0m
m加
6
日ご)一⑪孟曰⑪』。⑰の巴臼已冒。、
OFI:quency(Niz)’50F品uency(Hlz)’5
(a)PhenolfbrmaldehyderesmBinder(b)EAIBinder
Figurel6・BrakeSquealEvaluationTests
Thisreplacementofpolymerprovidesthesamelevelbrakeeffectivenessandtheremarkablebrakesquealreduction・BasedontheconsiderationofpolymerfrictionfOrcevariation,prototypepadmaterialwasdesignedfOrhigherfrictioncoefficientandlessbrakesqueal.
CoNCLUDINGREMARKS
(1)BrakeSquealiscausedbydynamicinstabiIity,whichdependsonitsdynamicunstabIestructureofvibrationsystemanditsdisturbanceoffrictionfOrcevariation・AssameasbrakestructurerefinementfOr
dynamicstabilityisrequiredfOrnobrakesqueal,thereductionoffrictionfOrcevariationisalsorequired.
(2)ThispapershowsthepossibilityofhigherbrakeperfOrmancewithlessbrakesquealinpadmaterials
design.Thehigherfrictioncoefficient似andthe
reductionofitsvariationcanbeprovidedbytherepIacementofstraightchaintypemoleculestructurepolymers.
2008年10月7日9時10分1158618
ⅡⅡ
茄懸寓椴蝋噸鮓1日且■月■外目F鋲.“⑯X凶幽P轡軒和懲抄wい』
■
迩感△》吋画{喝硴w睡師》且几(岾庇XX■B■H
RR
■
日Ⅱ■
xBR
鰍X
X
H;欺月月
日
NX
且
月
jWl 瀧仁に、から
鯉ISC?」Ⅱ-