FRICTION MATERIAL COMPOSITES
CONTENTS FRICTIONAL FORCE—INTRODUCTION INTRODUCTION BFMC—BRAKE FRICTION MATERIAL COMPOSITE—DEFINITION CHARACTERISTICS DEFINING THE SYSTEM NATURE OF BRAKE FRICTION MATERIAL COMPOSITE (BFMC) MECHANISMS MANIFESTING THE DYNAMICS BFMC SYSTEM—PROCESS DEFINITION OF BFMC SYSTEM PROPERTIES OF THE SYSTEM DYNAMICAL AND COMPLEX SYSTEMS BFMC SYSTEMIC ATTRIBUTES COMPLEX SYSTEMS—DEFINITION COMPLEX SYSTEMS DEFINITION OF COMPOSITE MATERIALS FRICTION MATERIAL COMPOSITES (FMC) BRAKE FRICTION MATERIAL COMPOSITES (BFMC) BRAKE FRICTION MATERIAL COMPOSITES (BFMC) WITH METAL MATRIX BRAKE FRICTION MATERIAL COMPOSITE (BFMC) WITH POLYMER MATRIX BRAKE FRICTION MATERIAL COMPOSITE MULTIMATRIX BASIC ISSUES OF FRICTION MATERIAL PARTICLE INTERPHASES DISK PAD ROTOR AND CALIPER ASSEMBLY AN ACCOUNT OF FRICTIONAL FORCE CHARACTERISTICS OF MOLECULAR FORCES WHAT IS A FRICTIONAL FORCE? WHAT HAPPENS IN A FRICTIONAL CONTACT SURFACE? TRANSFER FILM LAYER IN A FRICTIONAL CONTACT AREA NANOSTRUCTURE METALLIC MATERIALS FOR ENHANCED WEAR AND CONTROL ON FRICTION: BAN ON COPPER UNDER THE LEGISLATION BILLS SB6557 AND S 346 PASSED IN USA AND CALIFORNIA COMPOSITE COATINGS FOR FRICTION AND WEAR PROPERTIES GEOMETRICAL SURFACES AND THE FORCES OF FRICTION NEW CLASS OF QUASICRYSTALLINE MATERIALS ESSENTIAL VIRTUES OF BRAKE FRICTION MATERIAL COMPOSITE DIFFERENT TYPES OF COEFFICIENTS OF FRICTION TEST CONDITIONS OF ?–V TESTING—BMI (BISMALEIMIDE) POLYMERIC MATRIX-BASED COMPOSITE SYSTEM IN A NON-ASBESTOS TO ASBESTOS FORMULATIONS COMPARED COEFFICIENT OF FRICTION—BRAKE LINER FITTED WITH “S” CAM BRAKE WEAR RATE THERMAL DAMAGE VIRTUES OF A GOOD FRICTION MATERIAL KEY CHARACTERISTICS OF FRICTION MATERIAL COMPOSITE IN MEETING THE ABOVE SAID VIRTUES FADING FRICTION NOISE ELIMINATION SEQUENCE SEQUENCE TO CONTROL GOOD BRAKING, LOW WEAR WITH MINIMAL OR NO NOISE THE VIBRATION COMPONENTS FROM THE RADIAL DIRECTION OF THE ROTOR HAS THE FOLLOWING COMPONENTS NOISE SEARCH GRAPH NOISE OCCURRENCE WITH PRESSURE AND TEMPERATURE FREQUENCY VERSUS PEAK LEVEL DECIBELS IN RELATION TO TEMPERATURE SCALE TYPICAL NOISE SEARCH FOR VARYING AMPLITUDE COMPRESSIBILITY AND JUDDER VIBRATION-RELATED ISSUES IN A DISK PAD: COMPRESSIBILITY OF THE PAD—AND COLD HOT HIGH AND LOW SPEED JUDDER KINETIC COEFFICIENT OF FRICTION: THEORETICAL CONSIDERATIONS DESIGN ESSENTIALS—FRICTION MATERIAL COMPOSITE SYSTEM BRAKE AND VEHICLE DATA DATA COLLECTION BEFORE ATTEMPTING ANY DESIGN BASIC ENGINEERING CALCULATIONS TO DESIGN THE TORQUE FOR ANY VEHICLE MODEL—DATA ASSUMED LIMITING BRAKE TORQUE DESIGN DRAWING AS AN INPUT FROM THE ORIGINAL EQUIPMENT MANUFACTURER BRAKING RATIO INERTIA CONSTANTS TERRAIN/LANDFORM TOPOGRAPHY AS A DESIGN INPUT CONTACTING SURFACE—ROTOR DISK AND DRUM DETAILS AS A DESIGN INPUT FRICTION-INDUCED CHANGES AT THE ROTOR SURFACE BRAKE ROUGHNESS ROUGHNESS—VIBRATIONAL NOISE ROTOR WEAR ROTOR THICKNESS VARIATION DUE TO EXCESSIVE HEAT DISK BRAKE ROUGHNESS (DBR) MEASUREMENT AFM—BRAKE PAD ROUGHNESS ROUGHNESS MEASUREMENTS IN A DYNAMOMETER BRAKE DESIGN FACTORS—SLIDING CALIPERS THICKNESS VARIATION DUE TO MANUFACTURING REASONS ABRASIVE BRAKE PADS METALLOGRAPHIC STUDIES ON GRAY CAST IRON SAMPLES OF THE DRUM ROLLING MOTION PURE ROLLING MOTION SLIDING WEAR WEAR IN A RAIL BRAKING WHEEL DEFORMATION AND STATIC FRICTION TORQUE VERSUS ANGULAR VELOCITY TRANSLATIONAL KINETIC ENERGY VERSUS ROTATIONAL KINETIC ENERGY OF THE GYRATING MASS CIRCULAR MOTION—THEORETICAL CONSIDERATIONS ANGULAR DISPLACEMENT AND ANGULAR VELOCITY RELATION BETWEEN LINEAR AND ANGULAR VELOCITY ANGULAR ACCELERATION CENTRIPETAL ACCELERATION (UNIFORM CIRCULAR MOTION) TANGENTIAL ACCELERATION AND CENTRIPETAL ACCELERATION DYNAMICS OF UNIFORM CIRCULAR MOTION DYNAMICS OF NONUNIFORM CIRCULAR MOTION CONTENTS XI FORMULATION DESIGN ROLE OF FIBERS AND FILLERS TO BE CITED MATERIALS BEAR EFFECT ON FORMULATION AND PROCESS ZERO-, ONE-, TWO-, AND THREE-DIMENSIONAL FILLERS AND FIBERS AXIAL PLANAR REINFORCEMENT DISPERSION STRENGTHENED (PARTICULATE) COMPOSITES, STRUCTURE, AND PROPERTIES WHAT DOES A FRICTION MATERIAL COMPOSITE CONSTITUTE? SELECTION OF DESIGN OF EXPERIMENT DOE AS AN OPTION FRACTIONAL FACTORIAL DESIGN—BFMC SPECIFIC FUNCTIONAL ROLE OF MATERIALS IN BFMC—SYSTEM DEPENDENT FACTORS THAT CAN AFFECT FRICTION DESIGN CONTROL FOR—DESIGN OF “FRICTION MATERIALS COMPOSITE” DESIGN CONTROL FOR UNDERTAKING DESIGN OF PROCESS CONTROL DOCUMENTS TO BE GENERATED ALL HAVE TO BE NUMBERED AND INDEXED FOR CROSS REFERENCING—BFMC ACTIVITY CHART FOR DESIGN CONTROL OF “FRICTION MATERIALS” TECHNICAL DOCUMENTS REQUIRED FOR MANUFACTURE OF FRICTION MATERIAL DESIGN PRODUCT DESIGN ROUTE SELECTION FOR THE BRAKE SYSTEM IN OPERATION BFMC MANUFACTURER, SEQUENCE OF DESIGN APPROVAL PROCESS CRITICAL RAW MATERIALS USED IN BFMC DESIGN AND THEIR CHARACTERISTICS TYPICAL SPECIFICATION AND LEVEL OF DOSAGE USED IN A FRICTION MATERIAL FORMULATION GENERAL SPECIFICATION USED IN FRICTION MATERIAL COMPOSITE MOS2 SIMPLE MATERIAL SELECTION SEQUENCE INTERRELATIONSHIP BETWEEN MATERIAL, DESIGN AND PROCESS DESIGN PROCESS FOR BFMC SELECTION DISK PAD MATERIAL ORGANIC SEMIMETALLIC METALLIC CERAMIC BRAKE PADS AND LININGS SINTERED FRICTION MATERIAL CERAMIC POTASSIUM TITANATE FIBER-FILLED SYSTEM IN NON-ASBESTOS DESIGN—FUNCTIONAL MATERIAL CHARACTERISTICS DESIGN OF FORMULATION, PROCESS FOR THE ABOVE SAID GROUPS OF BRAKE PADS AND LINERS BRAKE SYSTEM AS AN ESSENTIAL INTEGRATION FOR A GOOD PERFORMING PAD, LINER MATERIALS POINT OF VIEW OF THE FORMULATION DESIGN CRITERIA FOR SELECTION OF MATERIALS FOR DESIGNING A FRICTION MATERIAL FORMULATION MATERIAL SPECIFICATIONS AS CONTROL IN A FORMULATION MATERIALS USED IN A FRICTION MATERIAL COMPOSITE FORMULATIONS FOR AUTOMOTIVE AND RAIL BRAKING APPLICATIONS INCLUDE BASIC PHYSICAL, THERMAL, AND MECHANICAL TESTS DONE ON A FRICTION MATERIAL FORMULATION—PROTOTYPE SAMPLES DESIGN OF EXPERIMENTS FRACTIONAL FACTORIAL DESIGN GENERAL GUIDING PRINCIPLES FOR A FRACTIONAL FACTORIAL EXPERIMENT IS GIVEN BELOW EXPERIMENTAL OBJECTIVE IMPORTANT CHARACTERISTICS DESIGN OF EXPERIMENTS: FACTORIAL EXPERIMENT DESIGN TABLES DETERMINE THE ACCEPTANCE CRITERIA PICKING UP THE ACCEPTANCE CRITERIA CALCULATING SAMPLES PER RUN BRAKE SHOE BONDING FACTORS AND LEVELS BFMC—PROCESSING PROCESS DESIGN CONTROL—PARAMETER MIXING, BLENDING, TUMBLING MIXER DESIGNS/CONFIGURATION MIXING SEQUENCE WITH TIME OF ADDITION EFFECTIVE HOMOGENIZATION—MEASURE SELECTION OF THE PRESS PRESS PARAMETERS—SAMPLE SPECIFICATION (DATA PROVIDED PURELY AS AN INDICATION OF SPECIFICATION) TO GIVE A BASIC ACCOUNT OF THE SEQUENCE OF OPERATION OF A PRESS IN ONE CYCLE—DISK PAD POSSIBLE HYDRAULIC PRESS ISSUES RELATED TO MAINTENANCE WHICH CAN NORMALLY HAMPER THE EFFICIENCY OF THE PRESS DESIGN CONTROL PLAN: DISK PAD MANUFACTURING PFMEA—PRODUCT FAILURE MODE EFFECT ANALYSIS PREDESIGN PLAN SIGNIFICANT CHARACTERISTICS DESIGN CONTROL PLAN DISK BRAKE PAD CONTROL PLAN DISK BRAKE PAD (PRESS LINE) IN-PROCESS INSPECTION MULTILAYERS HOT PRESS DISK BRAKE PAD (PRESS LINE) IN-PROCESS INSPECTION SINGLE LAYER HOT PRESS NUMBER: DISK BRAKE PAD FINAL INSPECTION DBP ATTACHMENTS INCOMING INSPECTION STORE SHIPMENT PACK QUALITY OBJECTIVES ZERO DEFECTS PRODUCTION REJECT MODES (PCS) PROCESS TRAVEL CONTROL CARD DISK BRAKE PAD INCOMING RAW MATERIAL INSPECTION RAW MATERIAL—MIXING, COATING, AND SIEVING DBP (FINISHING LINE) IN-PROCESS INSPECTION GLUE SPRAY AND OVEN DRYING IN-PROCESS INSPECTION RIVET INCOMING INSPECTION A GOOD MANUFACTURING LAYOUT TYPICAL TESTS DONE IN A BRAKE LINING, BRAKE PAD (EXCLUDE SOME OF THE TESTS FOR BRAKE PADS) NON-ASBESTOS BRAKE LINING BFMC—FORMULATIONS AND PROCESSES BACKUP LAYER HOT SHEAR TEST ON A BACKUP LAYER—SAMPLE DATA FORMULATIONS MOLDING PROCESS—BRAKE LININGS AND BRAKE PADS DRY MIX PROCESS HISTORY OF EVOLUTION OF SEMIMETALLIC DISK BRAKE PADS EVOLUTION OF NAO NOMENCLATURE AFTER SEMIMETALLIC AND METALLIC DISK PADS MIXING CYCLES—TIME AND SEQUENCE OF ADDITION AS AN IMPORTANT FACTOR CONTROLLING THE MIXING ACTION CONTROLLING MIXING EFFICIENCY CERAMIC AND NONASBESTOS ORGANIC FORMULAS HORSE POWER REQUIREMENTS WET MIX MIXING ACTION LAWS AND RULES GOVERNING FRICTION MATERIALS TOTAL QUALITY MANAGEMENT AN ACCOUNT OF COPPER-FREE, NON-METALLIC FRICTION MATERIAL DESIGNS—CURRENT ISSUES AND SOLUTION CERAMIC ROUTE AS A SOLUTION TO COPPER-FREE, NONMETALLIC BRAKE PAD DESIGN TECHNICAL ASPECTS OF AN EFFECTIVE CERAMIC MATERIAL BASIC UNDERSTANDING OF CERAMICS THROUGH ELECTRON MECHANISM THERMAL CONDUCTIVITY TEST REQUIREMENTS IN AN AUTOMOTIVE BFMC DESIGN WORLD CLASS TEST SPECIFICATIONS FOR DISK BRAKE PADS: METHODS OF TESTING, PROCEDURES WITH STANDARDS ELECTRICAL RESISTIVITY MEASUREMENTS IN BRAKE FRICTION MATERIAL COMPOSITE (BFMC) VOLUME RESISTANCE AND SURFACE RESISTANCE MEASUREMENTS FOR COPPER FREE, NON-METALLIC SYSTEMS AND OTHERS FOR BENCH MARKING AND COMPARISON ESSENTIAL PHYSICAL PROPERTIES ENUMERATED: NOT ALL TESTS ARE COVERED DENSITY SOLVENT EXTRACTION TEST FOR UNCURED RESIN IN THE MATERIAL: A VALUE <2 % IS HEALTHY >2 % SWELL IS POSSIBLE PARTICLE SIZE FOR 50 G SAMPLE POROSITY MEASUREMENT GORDEN KLINE—DETERMINATION OF HEXAMETHYLENE TETRAMINE—CURE CONTENT IN THE RESIN PH INDEX—HYDROGEN ION CONCENTRATION PAD SHEAR TEST WITH SHEAR FORCE TEST FOR COLD COMPRESSIBILITY OF THE PAD TEST FOR PAD SWELL 11 3 10 TEST FOR SWELL AND GROWTH BACKING PLATE SURFACE TREATMENT—CORROSION RESISTANCE SYSTEM OVERVIEW OF THE PASSENGER CAR DYNAMOMETER WORST CASE CRITERIA (WCC) TECHNICAL SPECIFICATIONS OF PASSENGER CAR DYNAMOMETER—ONE TYPE SCALED DOWN TEST FOR RAIL BRAKE FRICTION COMPOSITE REFERENCES