Orientador: Robson Pederiva / Dissertação (mestrado) - Universidade Estadual de Campinas, Faculdade de Engenharia Mecânica / Made available in DSpace on 2018-08-19T13:48:38Z (GMT). No. of bitstreams: 1 Suetti_AndreGarciaLima_M.pdf: 20585864 bytes, checksum: 84c85d26b6df77562a52c8ca3aa2aedf (MD5) Previous issue date: 2011 / Resumo: O interesse da indústria automobilística em projetar freios menos ruidosos vem incentivando pesquisas na área de acústica e vibração. A compreensão de um dos principais fenômenos de excitação de vibração em sistemas com atrito, o stick-slip, é de grande importância para o aprofundamento desses estudos, que muitas vezes não consideram uma fonte de excitação bem definida e realimentada, recorrendo a excitações impulsivas ou com frequências aleatórias. O stick-slip é uma vibração auto-excitada que pode ocorrer em um corpo fixo que se atrita com outro corpo que está em movimento, fundamentada na diferença entre o coeficiente de atrito estático e dinâmico. Tendo em vista a aplicação da excitação por stick-slip em vibrações em sistemas de freio, equacionamentos analíticos são propostos nesse trabalho tendo a dificuldade incrementada gradualmente. Um estudo dos efeitos do amortecimento em sistemas com stick-slip é também proposto, apresentando um comportamento que difere de sistemas mecânicos sem realimentação. Com o objetivo de se avaliar esses métodos, realizam-se simulações numéricas e um experimento, que se utiliza de materiais de atrito e disco empregados em freios. Os resultados demonstram a compatibilidade das simulações numéricas e os dados obtidos experimentalmente, o que comprova que os métodos podem ser usados na simulação do problema / Abstract: Interest of the automotive industry in designing quieter brakes has encouraged the researches in the fields of acoustics and vibration. Understanding one of the main phenomena of vibration excitation in systems with friction, stick-slip, is crucial to a deeper study. Many a time these studies do not consider a well-defined and fed back source, falling back on impulsive and random excitations. The stick -slip is a self-excited vibration that may occur when a static body rubs against a dynamic one. It is based on the difference between the static and dynamic friction coefficients. Considering the stick-slip excitation in the braking system vibration, analytical equations with continuous incremental difficulties are proposed herein. A study of the effects of damping in stick -slip systems is also proposed, presenting a kind of behavior that is different from that of mechanical systems without feedback. In order to evaluate these methods, an experimental or sometimes numerical simulation is conducted using friction material and discs used in braking systems. The results are in agreement with the experimental data, proving that the methods can be used in simulations of problems / Mestrado / Mecanica dos Sólidos e Projeto Mecanico / Mestre em Engenharia Mecânica

Submitted in fulfillment of the requirements for the degree of Master in Engineering: Mechanical Engineering, Durban University of Technology, Durban, South Africa, 2017. / Despite the huge improvements made in the development of vehicle brake pad materials, problems such long stopping distances, noise pollution, and heat dissipation still continue to persist. In this regard, a novel polymer-based hybrid nanocomposite brake pad (HC) has been developed. Here, a combination of carbon-based materials, including those at a nanoscale, was used to produce the brake pad. The coefficient of friction, wear rate, noise level, and interfacial temperature was investigated and compared with that of a commercial brake pad material (CR). It was found that the brake pad performance varied with the formulation of each pad. Hybrid nanocomposite brake pads material exhibited superior performance in most tests when compared to the commercial brake pad. They exhibited a 65% lower wear rate, 55% lower noise level, 90% shorter stopping distance, and 71 % lower interfacial temperature than the commercial brake pad (CR). Furthermore, mechanical properties such as hardness, compressive strength, shear strength, and impact resistance were also evaluated. The material exhibited a 376% higher shear strength, 100% improved compressive strength, 77% greater modulus and 100% higher impact strength than the commercial brake pad. The hardness of both brake pads material was statistically comparable. Additionally, the thermal stability, degradation, water and oil absorption behaviour were measured. It was found that HC brake pad material exhibited a 100% lower water absorption and 80% oil absorption rate. The brake pads also exhibited a thermal stability within the brake pad standard maximum working temperature of 300 -400 0C. The superior performance of hybrid nanocomposite brake pad material observed was due to synergism between the carbon-carbon additives and uniform dispersion of carbon fiber as shown in Figure 4.16. Scanning electron microscopy study was subsequently performed on fracture and worn surfaces of the brake pads. The micrographs show changes in the structural formation after the incorporation of carbon based fillers. It also shows the smooth structure and uniform dispersion of the carbon fiber. The smooth surface of the worn brake pad is an indicative of a harder structure. No ploughing or score marks were evident. Hence, it was deduced that the reinforced had superior mechanical and tribological properties. These improved properties are suggestive of materials that may be successfully used for brake pad application. / M

Describe entire information about design of respective component in Formula (category Student) braking system is object of this thesis. Processing is divided to four main areas. The first one describes basic components in braking system, which goes on analysis of braking system in present used Formula Student Dragon 1. The second one, more spread part, consists of braking system proportioning for Formula Student Dragon 2, respecting pieces of knowledge from first generation Formula. The third part involves design single components of braking system for second generation Formula. This design is supported by measurements and results of calculations. The conclusion of master thesis involves design of caliper model and its FEM analysis.

During braking, both the rotor and the pads in disc brakes are worn. Since disc brakes are not sealed, some of the wear particles generated can become airborne. Several studies have found an association between adverse health effects and the concentration of particles in the atmosphere, so it is of interest to improve our knowledge of the airborne wear particles generated by disc brakes. However, in field tests it is difficult to distinguish these particles from others in the surrounding environment, so it may be preferable to use laboratory test stands and/or simulation models to study the amount of airborne wear particles generated. This thesis deals with a simulation methodology for prediction of airborne wear particles from disc brakes and three experimental methods for testing disc brake materials with focus on airborne wear particles. The four appended papers discuss the possibility to both measure and predict the number and size distribution of airborne wear particles that originate from the pad to rotor contact. The objective is to develop a simulation methodology that predicts the number and size distribution of airborne wear particles from disc brakes. Paper A describes how a modified pin-on-disc machine was used to study airborne wear particles originating from different disc brake materials. The results indicate that the test setup can be used to measure and rank the number concentration and size distribution of the airborne wear particles generated. Paper B describes a disc brake assembly test stand for measurements of airborne wear particles from disc brakes. The results indicate that the test setup can be used to measure the number concentration and size distribution of airborne wear particles generated from disc brake materials. The results also indicate a promising ability to rank different pad/rotor material combinations with respect to the number concentration of airborne wear particles. Paper C compares measurements made in passenger car field tests with measurements made in a disc brake assembly test stand and in a pin-on-disc machine. A promising correlation between the three different test methods is found. Paper D presents a simulation methodology for predicting the number and size distribution of airborne wear particles using finite element analysis (FEA). The simulated number distribution is compared with experimental measurements at component level. The result indicates that the proposed methodology may be used to predict the number concentration and size distribution of airborne particles generated in the pad-to-rotor contact.

No / Given that most of the working life of a brake pad life is spent in the bedded condition, it is important to examine the conditions of a fully bedded contact interface. An experimental and a numerical method are combined. Contact pressure and its effects (heat generation/partition and temperature rise) for the drag braking process with and without bedding are compared. The real contact area is also measured and found to be increased for the bedded interface. This results to the contact pressure being ¿more¿ evenly distributed than before. Spreading the contact pressure also results in increasing the total heat transfer between the disc and pad since now more heat can be transferred from the pad (where it is generated) to the disc. It is concluded that in order to have a reliable simulation it is recommended that the bedding-in effects are introduced in the simulations. / IMechE, RAE Travel Grant

This dissertation details the methods and analysis of extensive physical tests and simulation conducted by the Center for Vehicle Systems and Safety (CVeSS) at Virginia Tech on the maneuverability, roll-stability, and brake type performance of 33-ft double trailers. Little literature exists for 33-ft doubles because they are uncommon on the U.S. roads due to current federal restrictions limiting long-combination vehicles to 28-ft doubles. With the continual rise in e-commerce, however, there is a push by package carriers on legislation to permit carriers to introduce 33-ft doubles into their fleets. Three separate studies detailed herein highlight 33-ft double trailers' off-tracking, roll-stability with stability control systems, and brake type influence on braking performance. The first study compares low-speed off-tracking of a 33-ft double to 28-ft double and 53-ft single configurations via simulation and full-scale tests. Novel numerical tractrix models are introduced and compared to existing models commonly used to evaluate low-speed off-tracking of long combination vehicles (LCVs). Unlike pre-existing models, accuracy of one of the proposed models is largely unaffected by input path resolution and regularity—a significant benefit for reducing computational cost and easing implementation for many applications. Full-scale tests are conducted at Virginia Tech and an extensive uncertainty analysis is detailed for the test procedure and measurements. Field tests compare favorably with simulations for all tested maneuvers and trailer configurations and clearly demonstrate the order from least to most off-tracking as 28-ft double, 33-ft double, and 53-ft single. The 33-ft doubles have slightly larger off-tracking than 28-ft doubles, whereas 53-ft singles have substantially larger off-tracking than 28-ft and 33-ft doubles. The second study evaluates 33-ft double straight-rail trailers rollover propensity with different stability control system implementations: stock (none), tractor electronic stability control (ESC), trailer roll-stability control (RSC), and RSC+ESC. Extensive test vehicle instrumentation and structural reinforcement are detailed for the test preparations. Tests are conducted on a test track with either driver or robot steering. On their own, both ESC and RSC clearly reduce the rollover propensity of the trailers for all maneuvers, and the trailers exhibit the highest roll-stability when both RSC and ESC are active. The tested ESC and RSC modules are off-the-shelf products from industry suppliers chosen by the program sponsor. The third study compares trailer drum and disc brake performance in three conditions: straight-line braking distance, brake type influence on RSC performance, and roll dynamics in a combined braking and turning maneuver. A braking robot is designed, fabricated, and implemented to provide precise and repeatable brake pedal application. Test results suggest that disc brakes tend to provide reduced braking distance and are less susceptible to brake fade than drum brakes. Anti-lock braking system (ABS) and suspension dynamics react differently to the two brake types. Small, noticeable differences in RSC performance are evident between the two brake types. Within the test limitations, rollover dynamics were not clearly different between the two brake types for braking-in-turn maneuvers, performed for a large range of entry speeds and brake activation delay relative to the start of steering. / Doctor of Philosophy / Due to their large size, mass, and high center-of-gravity, heavy vehicles, especially long combination vehicles (LCVs) require a substantial amount of space to negotiate turns, long distances to brake from highway speeds to a stop and are susceptible to rollover. Combination vehicles on the U.S. roads are commonly in 53-ft single trailer or 28-ft double trailer configurations. With the continual rise of e-commerce, package carriers are pursuing 33-ft double trailers to increase each vehicle's cargo volume. Before introducing these trailers into a fleet, there is a need to understand (1) if 33-ft doubles can negotiate existing routes traveled by 28-ft double and 53-ft single configurations, (2) if 33-ft doubles can benefit from existing stability control systems, and (3) how trailer brake types perform on 33-ft doubles. Three separate studies are conducted to address these topics. The first study compares off-tracking for the three mentioned trailer configurations through low-speed, real-world maneuvers via physical full-scale tests and simulation. Off-tracking is a metric illustrative of maneuverability and is defined as the relative distance in paths of the rearmost axle to the lead steer axle. New mathematical models are introduced and used to simulate vehicle motion through low-speed maneuvers. The simulation and field tests determine that, for all tested maneuvers, the order from smallest to largest off-tracking is 28-ft double, 33-ft double, and 53-ft single configurations, with the 33-ft doubles having slightly larger off-tracking than 28-ft doubles. This suggests that 33-ft doubles can travel through routes typically traveled by a 53-ft single but need slightly more space on the road than a 28-ft double. The second study tests 33-ft double trailers with and without stability control systems. Tests, conducted at a test track, are designed to replicate real-world maneuvers that induce trailer rollover. It is found that the 33-ft double trailers are clearly less likely to rollover with the tested stability enhancement systems than without. The tests also illustrate that the different tested control systems' effectiveness in reducing rollover propensity is maneuver dependent. The third study tests the braking distance, brake influence on the stability control systems, and rollover dynamics while braking-in-turn for two different types of brakes, drum brakes and disc brakes. Small but evident differences in the performance of the two brake types suggest disc brakes could provide shorter stopping distance and time at highway speeds, compared with drum brakes. The studies detailed in this dissertation provide valuable information on 33-ft doubles dynamics and provide guidance for their safe introduction on the U.S. roadways.

This master’s thesis focused on the issue of the possible conversion of liquid brake systems, in the form of replacement of wheel brakes. The first part focused on the function and description of the construction of different types of brakes. The second part is focused on description the types of brake system testing and the regulations regarding brake systems. The last part focused on the measurement of both vehicles and comparison of the results with the calculations.

Over the past decade vehicle judder caused by Disc Thickness Variation (DTV) has become of major concern to automobile manufacturers worldwide. Judder is usually perceived by the driver as minor to severe vibrations transferred through the chassis during braking [1-9]. In this research, DTV is investigated via the use of a Smart Brake Pad (SBP). The SBP is a tool that will enable engineers to better understand the processes which occur in the harsh and confined environment that exists between the brake pad and disc whilst braking. It is also a tool that will enable engineers to better understand the causes of DTV and stick-slip the initiators of low and high frequency vibration in motor vehicle brakes. Furthermore, the technology can equally be used to solve many other still remaining mysteries in automotive, aerospace, rail or anywhere where two surfaces may come in contact. The SBP consists of sensors embedded into an automotive brake pad enabling it to measure pressure between the brake pad and disc whilst braking. The two sensor technologies investigated were Thick Film (TF) and Fibre Optic (FO) technologies. Each type was tested individually using a Material Testing System (MTS) at room and elevated temperatures. The chosen SBP was then successfully tested in simulated driving conditions. A preliminary mathematical model was developed and tested for the TF sensor and a novel Finite Element Analysis (FEA) model for the FO sensor. A new method called the Total Expected Error (TEE) method was also developed to simplify the sensor specification process to ensure consistent comparisons are made between sensors. Most importantly, our achievement will lead to improved comfort levels for the motorist.

This thesis studies the design of an electro-hydraulic landing gear and brakes control system of a trainer aeroplane. In the first part there is a basic draft of the landing gear kinematics and its loads during gear retraction, flight and landing. Braking conditions are also analysed. The thesis then focuses on the design of hydraulic circuits and their control. Simulations for studying the dynamic characteristics of the braking proportional valve and the course of plane braking were created in Simulink. There is also a brief section about reliability of the proposed system.

<p>During braking, both the rotor and the pads in disc brakes are worn. Since disc brakes are not sealed, some of the wear particles generated can become airborne. Several studies have found an association between adverse health effects and the concentration of particles in the atmosphere, so it is of interest to improve our knowledge of the airborne wear particles generated by disc brakes. However, in field tests it is difficult to distinguish these particles from others in the surrounding environment, so it may be preferable to use laboratory test stands and/or simulation models to study the amount of airborne wear particles generated.</p><p>This thesis deals with a simulation methodology for prediction of airborne wear particles from disc brakes and three experimental methods for testing disc brake materials with focus on airborne wear particles. The four appended papers discuss the possibility to both measure and predict the number and size distribution of airborne wear particles that originate from the pad to rotor contact. The objective is to develop a simulation methodology that predicts the number and size distribution of airborne wear particles from disc brakes.</p><p>Paper <strong>A</strong> describes how a modified pin-on-disc machine was used to study airborne wear particles originating from different disc brake materials. The results indicate that the test setup can be used to measure and rank the number concentration and size distribution of the airborne wear particles generated.</p><p>Paper <strong>B</strong> describes a disc brake assembly test stand for measurements of airborne wear particles from disc brakes. The results indicate that the test setup can be used to measure the number concentration and size distribution of airborne wear particles generated from disc brake materials. The results also indicate a promising ability to rank different pad/rotor material combinations with respect to the number concentration of airborne wear particles.</p><p>Paper <strong>C</strong> compares measurements made in passenger car field tests with measurements made in a disc brake assembly test stand and in a pin-on-disc machine. A promising correlation between the three different test methods is found.</p><p>Paper <strong>D</strong> presents a simulation methodology for predicting the number and size distribution of airborne wear particles using finite element analysis (FEA). The simulated number distribution is compared with experimental measurements at component level. The result indicates that the proposed methodology may be used to predict the number concentration and size distribution of airborne particles generated in the pad-to-rotor contact.</p>