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Page 1: AStudyonFrictionMaterialshrBrakeeSquealReduction …machls.cc.oita-u.ac.jp/kenkyu/kei/bunken/data/masatsu/M... · 2012-05-11 · frictioncoefficient似variationinhighertemperatureof

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[,

Page 2: AStudyonFrictionMaterialshrBrakeeSquealReduction …machls.cc.oita-u.ac.jp/kenkyu/kei/bunken/data/masatsu/M... · 2012-05-11 · frictioncoefficient似variationinhighertemperatureof

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

|§;

!

_』

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

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

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 》

閑=E3

=n画eh面

腱=

「b(meud)l/2

一》γ

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

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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

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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

(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

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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.

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

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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』

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(3)ThehigherfrictioncoefficienMandthereductionof

itsvariationcanbeprovidedbythethreesuitabIecharacteristics,poIymerchainsdensiIyNchain>6,NumberofFENEPolymerfOrpersistencelengthNbids-1p〉6,FENEspringrigidityconstantskFENE>50.TherefinedpadmaterialproductswilIbedevelopedafterotherrequirementsstudies,fade,wear,andsoon.

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(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",

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(1963).6.G.DLiles,,,AnaIysisofDiscBrakeSquealUsingFinite

ElementMethods,,,SAEPaper,891150(1989).7.Y・SasakiandSKusaka,”TheTransitionof

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JapaneseSocietyofTriboIogists,Vol、41,N0.4,

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TransferredSurfaceFilmon似BehaviorofDisc

BrakePadinHumidityEnvironment",SAEPaperNo、

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designmethodanddesignsystem,',JapanPatentApplicationNumber2005-163662(2005).

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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

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0m

m加

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.

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