Automotive brake systems are source of particulate matter (PM) emissions, particularly in the urban areas. Several human ill-health are related with this kind of pollution. Along tire wear, road wear and dust from resuspension, the brake wear comprises the most relevant non-exhaust source of road traffic related emissions. Aiming at studying the PM brake emissions, this thesis is composed of an introductory part containing the main concepts and the state of art of the main subjects; and the experimental part, which comprehends three investigations. Chapters 2, 3, 4 and 5 are dedicated to the introduction part. Chapter 2 provides a brief description of the friction and wear, as well as the fundamental principles of braking by contact. Chapter 3 discuss the disc braking system, with particular attention to the pad friction materials. Chapter 4 is dedicated to friction layer: the layer usually developing at the disc/pad interface, affecting the performances of the tribological system. Finally, Chapter 5 provides an extensive discussion of the issues related to the particulate matter originated from disc brake systems. The experimental part is presented in the Chapters 6, 7, 8 and 9. Chapter 6 describes the methodology applied in all the investigations. Chapter 7 investigates the PM emissions behavior and its interaction with the friction and wear, aiming to identify the mechanism of generation the PM emissions. A copper-containing and a copper-free commercial friction materials were used, with particular emphasis on the effect of the scorching treatment. The Chapter 8 is dedicated at investigating the tribological behavior and the corresponding PM emissions in two Cu-free commercial friction materials, aiming to a better understanding the effect of abrasive ingredients on the emissions generation. Finally, the Chapter 9 investigated the addition of natural ingredient rice husk in a new eco-friendly Cu-free brake friction material composition, focusing the attention on the tribological and emissions behavior. All tests were carried out using a pin-on-disc tribometer equipped with an enclosure, especially designed for investigating the tribological properties, as well as the airborne particles generated by contact. Low-metallic friction materials, both commercial and laboratory-produced, were tested against cast iron discs. The tests parameters used correspond to mild sliding conditions resembling those faced in real braking. Such conditions are characteristic of driving in urban areas, where the expose to traffic PM is concentrated. A specific methodology of analysis was developed, based on SEM/EDXS techniques. Using this methodology, comparative investigations between the elemental composition of the virgin friction materials, the worn surfaces of the friction materials and the airborne particles collected during the tribological tests were carried out. The results point out the triboxidative wear as the main mechanism of the PM brake emissions generation. Moreover, particles produced by abrasive wear can be also directly emitted to the environment.

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The primary goal of this work is to design and implement a clutch and brake system on the single tire Terramechanics rig of Advanced Vehicle Dynamics Laboratory (AVDL) at Virginia Tech. This test rig was designed and built to study the performance of tires in off-road conditions on surfaces such as soil, sand, and ice. Understanding the braking performance of tires is crucial, especially for terrains like ice, which has a low coefficient of friction. Also, rolling resistance is one of the important aspects affecting the tractive performance of a vehicle and its fuel consumption. Investigating these experimentally will help improve tire models performance. The current configuration of the test rig does not have braking and free rolling capabilities. This study involves modifications on the rig to enable free rolling testing when the clutch is disengaged and to allow braking when the clutch is engaged and the brake applied. The first part of this work involves the design and fabrication of a clutch system that would not require major changes in the setup of the test rig; this includes selecting the appropriate clutch that would meet the torque requirement, the size that would fit in the space available, and the capability to be remotely operated. The test rig's carriage has to be modified in order to fit a pneumatic clutch, its adapter, a new transmission shaft, and the mounting frame for the clutch system. The components of the actuation system consisting of pneumatic lines, the pressure regulator, valves, etc., have to be installed. Easy operation of the clutch from a remote location is enabled through the installation of a solenoid valve. The second part of this work is to design, fabricate, and install a braking system. The main task is to design a customized braking system that satisfies the various physical and functional constraints of the current configuration of the Terramechanics rig. Some other tasks are the design and fabrication of a customized rotor, selection of a suitable caliper, and design and fabrication of a customized mounting bracket for the caliper. A hydraulic actuation system is selected since it is suitable for this configuration and enables remote operation of the brakes. Finally, the rig is upgraded with the assembly of these two systems onto it. / Master of Science / The main goal of this project is to increase the testing capabilities of the single tire Terramechanics rig of Advanced Vehicle Dynamics Laboratory (AVDL) at Virginia Tech. The first task is to enable the rig to have the tire in free rolling condition. This will allow to study rolling resistance of the tire on various off-road conditions such as soil, sand, etc. The free rolling capability will also allow evaluation of the rolling radius of a tire. A customized clutch system was designed to achieve this free rolling requirement. The second task of this project was to implement braking capabilities to the rig. Apart from the traction performance of tires on off-road conditions such as ice, the other parameter is its performance during braking as it is an important factor leading to safety on roads. A customized disc brake system is designed to add braking capabilities to the rig. This free rolling and braking systems has to implemented taking into account the various physical and functional constraints of the rig. The work involves the design and fabrication of various customized components followed by the assembly of these components along with their actuation systems.

Yes / To investigate the heat partition on a vehicle disc brake, a small scale test rig with one contact interface was used. This allowed the disc/pad contact temperatures to be measured with fast-response foil thermocouples and a rubbing thermocouple. Based on the experimental conditions a 3D symmetric disc brake FE model has been created. Frictional heat generation was modelled using the ABAQUS finite element analysis software. The interface tribo-layer which affects heat partitioning was modelled using an equivalent thermal conductance value obtained from the authors¿ previous work. A 10 second drag braking was simulated and the history and distribution of temperature, heat flux multiplied by the nodal contact area, heat flux leaving the surface and contact pressure was recorded. Test rig and FE model temperatures were compared to evaluate the two methods. Results show that heat partitioning varies in space and time, and at the same time contact interface temperatures do not match. It is affected by the instantaneous contact pressure distribution, which tends to be higher on the pad leading edge at the inner radius side. They are also affected by the thermal contact resistance at the components contact interface. / IMechE

Squeal noise has been an on-going concern with automotive brake systems since their inception. Even after many decades of research no single theory exists that adequately describes the phenomenon, and no general methods for eliminating squeal noise exist. Broadly speaking, three primary methods of analysis have been applied to understanding and eliminating brake squeal: analytical, experimental and numerical. Analytical models provide some insight into the mechanisms involved when a brake squeals, but have limitations in applicability to specific brake systems. Experimental methods provide the backbone of brake squeal investigations, especially in an industrial environment. However, the core focus of this thesis is to use a large scale finite element analysis (FEA) model to investigate brake squeal. Initially the FEA model was developed and the dynamic characteristics were validated against experimental modal analysis results. A complex eigenvalue analysis was performed to identify potential squeal modes which appear as unstable system vibration modes. Further techniques are described that allow the deeper probing of unstable brake system modes. Feed-in energy, which is the conversion of friction work into vibrational energy during the onset of squeal, is used to determine the relative contribution of each brake pad to the overall system vibration. The distribution of the feed-in energy across the face of a brake pad is also calculated. Component strain energy distributions are determined for a brake system as a guide to identifying which components might best be modified in addressing an unstable system mode. Finally modal participation is assessed by calculating the Modal Assurance Criterion (MAC) between component free modes and the component in the assembly during squeal. This allows participating modes to be visualised and aids in the development of countermeasures. The majority of the work in this thesis was performed using the commercial FEA code MSC.Nastran with user defined friction interfaces. An alternative approach using a contact element formulation available in Abaqus was also implemented and compared to the MSC.Nastran results. This analysis showed that considerable differences were noted in the results even though the overall predicted stability correlated relatively well to observed squeal. Abaqus was also used in a case study into the design of a brake rotor in a noisy brake system. The results of this study provided good correlation to observed squeal and facilitated effective rotor countermeasures to be developed. Some success was achieved in the main aims of predicting brake squeal and developing countermeasures. However, while the tools presented do allow a deeper probing of system behaviour during squeal, their use requires good correlation to observed squeal on brake system to be established. As such, their use as up-front design tools is still limited. This shortcoming stems from the complexity of brake squeal itself and the limitations in modelling the true nature of the non-linearities within a brake system.

Sufficient heat dissipation is crucial to the effective operation of friction based braking systems. Such cooling is generally provided by ensuring a sufficient supply of cooling air to the heated components, hence the aerodynamics in the region of the brake components is extremely important. The objective of the research was to develop an understanding of how aerodynamics could be used to improve the cooling of automotive disc brakes. Two separate sets of wind tunnel experiments were developed. Tests were performed on a vented disc (rotor) to measure the internal flow through the vents on a rotating vented disc under various conditions, including an isolated disc in still air, the disc in still air with the wheel on, the disc in moving air with the wheel on, and an on-road simulation using a ¼ car. On vehicle tests were also performed in a wind tunnel using a purpose built brake test rig. These tests measured the thermal performance of different brake discs under various operating parameters; including constant load braking, and cooling from high temperature under various speeds, wheels and disc types. It was found that airflow through vented rotors was significantly reduced during simulated on-road driving, compared to when measured in isolation, but not particularly affected by the vehicles speed. In the situations tested, vented discs offered a 40+% improvement in cooling over an equivalent sized solid rotors. However the research indicates that the greatest benefit of vented rotors over solid will be in vehicles where air entering the wheel cavity is limited, such as low drag vehicles. It was also found that the most significant improvements in brake thermal performance could be achieved by maximising the airflow into the region of the brake components; including increasing the open area of the wheel, and increasing the vehicle velocity. Other improvements can be achieved by using a wheel material with good conductive capability, and increasing the mass of the disc. Evidence of vortex shedding was also discovered in the airflow at the exit of an internal vented rotor, any reduction in this flow disturbance should lead to increased airflow with associated improvements in thermal performance.

This report represents the bachelor thesis examination by Julia Kastehelmi Rintamäki. The examination has been performed during spring semester 2013 at Volvo Construction Equipment in Eskilstuna. This report, Development of parking brake component, describes the product development process of the parking brake component for articulated hauler, wheel loader and grader. Volvo CE has problems with the parking brake switch that exist today on articulated hauler, wheel loader and grader. The purpose of this project is to develop one common solution for the parking brake component for articulated hauler, wheel loader and grader. The secondary purpose is to find final concept proposal for each machine. Employees at the Volvo CE were interviewed; they were contacted via e-mail, phone calls and via meetings to get the information about the machines and the information around the parking brake component. Volvo CE databases were also used for gathering information about standards and pictures. Lots of different ideas were sketched and concept proposals were created with the aid of material from marketing analysis, competitor analysis, target group analysis, requirement specification, function analysis, standards and ergonomics. Eight concept proposals were chosen to be evaluated with QFD, Pugh’s matrix and FMEA. Two concepts were most suitable and developed further to three dimensional models with the aid of Solid Works. The different aspects were taken into account when designing and dimensioning the final concepts. Two models were created with the aid of plasticine for figuring out the ergonomics and dimensions of the product. DFM, DFA, DFE, D4S were used for taking into account costs, assembly, dimensions and environmental impacts of this product. One of the concepts could replace the existing parking brake switch and suit in different cabins because of its size and design. This concept can be located on vertical or on horizontal plane. The other final concept solution functions better for the  articulated hauler on account of the double function with exhausting brake system activating before parking brake system. Suggestion for next steps for the project could be to make prototypes of the two concepts and test these components in real machines. Also interviewing users for further development of the final concepts and redesign if needed.

Since the investigation of wear particles from rail transport started in the late 1910s, the high mass concentrations of these particles have prompted concern among researchers interested in air quality. However, effective action has yet to be taken because relevant knowledge is still missing. This thesis provides knowledge of airborne wear particles originating from rail transport. Some aspects of their characteristic parameters, such as size, mass concentration, number concentration, and morphology, were investigated in the field and in laboratory tests. We also discuss means to mitigate non-exhaust emissions, as well as the advantages and disadvantages of various test set-ups in the seven appended journal papers:Paper A reviews recent studies of exhaust and non-exhaust emissions from rail vehicles. The results, measurements, adverse health effects, and proposed or applied solutions presented in this literature are summarized in this paper.Paper B summarizes the results of field tests we conducted. The effects of curve negotiation and braking under different real conditions were investigated in a field test in which on-board measurements were made. The elemental composition and morphology of the particles emitted and their potential sources were also investigated.Paper C describes how a pin-on-disc machine can be used to reproduce real operating conditions during mechanical train braking in a controlled laboratory setting. The results were validated by comparing the field test results with the results of laboratory studies.Paper D presents comprehensive results of laboratory studies of airborne particles from different braking materials. A new index is introduced in this paper, which can be used as a quantitative metric for assessing airborne wear particle emission rates.Paper E describes the effects of using various friction modifiers and lubricants on the characteristics of airborne particles from wheel–rail contact under lubricated and unlubricated conditions.Paper F reports work to simulate thermoelastic instability in the cast-iron braking material. We simulated the fluctuation of the flash temperature by considering the temperature dependency of the material properties and the transformation of the contact state due to thermomechanical phenomena and wear.Paper G reviews new full- and sub-scale measurements of non-exhaust emissions from ground transport. The advantages and disadvantages of on-board measurements, pin-on-disc tests, dynamometer tests, and test rig studies are discussed in this paper. / <p>QC 20131025</p>

This Diploma Thesis is dedicated to solve the source of noise, observed during braking processes on tested vehicle, called Gouki noise and has been worked out in corporation with Federal Mogul company. The aim of this work to create test methology, which allows to experimentally detect the source of undesirable noise and eventually suggest next steps in its prevention.

The aim of this thesis is the analysis of three types commonly used automotive brake discs in terms of their thermal and mechanical resistance on a defined braking maneuver. Another objective is to make an evaluate of the different structural solutions and compare them by each other.