Professional Documents
Culture Documents
Tej Singh, Amar Patnaik, Brijesh Gangil, Ranchan Chauhan: Sciencedirect
Tej Singh, Amar Patnaik, Brijesh Gangil, Ranchan Chauhan: Sciencedirect
Wear
journal homepage: www.elsevier.com/locate/wear
art ic l e i nf o a b s t r a c t
Article history: This research work examined brake friction materials containing nanoclay and multi-wall carbon
Received 9 August 2014 nanotube (MWCNT) to determine their effect on the tribo-performance. The tribo-performance of brake
Received in revised form friction materials were investigated using a Kraus friction testing machine conforming to the Regulation-
18 November 2014
90 as per the ECE (Economic Commission for Europe) norms. The result of experiment indicated that
Accepted 20 November 2014
Available online 5 December 2014
MWCNT enhances the friction and fade performance, but depresses the wear performance, whereas
nanoclay improves the wear and recovery performance but simultaneously depresses the friction
Keywords: performance as well. Variability coefficient improves with nanoclay contents whereas, friction fluctua-
Friction material tions (μmax–μmin) improve with MWCNT content. Preference selection index (PSI) method was applied to
MWCNT
rank the friction materials by using several performance defining criterions (PDC) including coefficient of
Nanoclay
friction (μ), wear, friction recovery-%, friction fade-%, stability coefficient, variability coefficient, friction
Optimization
PSI fluctuation and disc temperature rise, respectively. These results show that the best combination of
tribological properties was exhibited by nanoclay filled formulation.
& 2014 Elsevier B.V. All rights reserved.
http://dx.doi.org/10.1016/j.wear.2014.11.020
0043-1648/& 2014 Elsevier B.V. All rights reserved.
T. Singh et al. / Wear 324-325 (2015) 10–16 11
tribo-performance analysis of fly ash based friction composites. become a great interest for assessment of tribo-performance in
The relative weight of importance of the criterions was deter- braking circumstances [25]. Over the past years, material scientist
mined by AHP (Analytic Hierarchy Process). The ranking of the and formulation designers have studied the effect of nano-fillers
friction materials has been carried out by TOPSIS (The Technique on the tribo-performance of brake friction materials [26–33]. Most
for Order Preference by Similarity to Ideal Solutions) method. Zhu of those studies mentioned the individual aspect of particular
et al. [18] used AHP and PROMETHEE (Preference Ranking Orga- nano-fillers like, nano alumina [26], nano silica [27], nano pow-
nization Method for Enrichment Evaluations) in order to select the dered rubber [28], carbon nanotubes [29–31], nanoclay [32], nano
optimal friction material formulation according to several criter- copper [33] and comparative aspects of nano-fillers were also
ions that were conflicting. Similarly, Singh et al. [19,20] imple- conjointly mentioned to some extent [34]. Despite of these
mented hybrid AHP-TOPSIS technique for evaluation and ranking studies, it is still tough to create any clear conclusion on the role
of multi-walled carbon nanotube based friction formulations. of nano-fillers in brake friction formulations. Thus it absolutely felt
Lu [21] and Han et al. [22] used golden section sequence and necessary to own a typical platform to match the performance of
component permutation with relational grade analysis as an nano-fillers. Therefore, the present research work focuses on the
experimental design tool for the development of brake friction development and tribo-performance evaluation of unfilled/nano
material. filled friction composite materials. Finally, an optimization tech-
Albeit, a number of MCDM methods were available in the nique has been implemented in order to find out the best friction
literature to enable the formulation designers to cull best for- material combination based on their performance defining criter-
mulation, it was observed that in some of these methods, the ions by using PSI method.
alternative ranking was affected by the criterion weight, whereas
some methods are quite arduous to understand and intricate to
implement requiring extensive mathematical erudition. Thus, 2. Experimental procedure
there is still requisite of a logical, systematic and simple method
to solve the friction material selection problems. As compared to 2.1. Fabrication of composites
other MCDM methods, preference selection index (PSI) method
was more facile to understand as it involves less numerical Friction composite formulation containing proportions of nano-
calculations [23,24]. The PSI method was considered a novel tool filler (nanoclay (Southern Clay USA) and MWCNT (Nanoshel, USA))
for selection of the best alternative among multi-alternatives to graphite (Graphite India Limited) are shear mixed with fixed
without deciding the relative importance between criterions; amount of Kevlar fibre (IF 258; Twaron, Teijin-Germany), lapinus fibre
instead the overall preference value of criterions was calculated (RB-220, Lapinus intelligent fibres, Holland), phenol-formaldehyde
utilizing the concept of statistics. Hence, it finds usability when resin of Novolac type (JA-10) and Barium Sulphate (BaSO4), amounting
there are conflicts in deciding the relative importance between to 100% by weight as depicted in Table 1. The composite fabrication
criterions. conditions during compression molding are given in Table 2.
Technically growths in non-asbestos fibre reinforced brake
friction materials has been achieved, but still they are reported
to be vulnerable to many braking induced performance defining 2.2. Tribological performance evaluation methodology
criterions as compared to asbestos based friction materials. In this
consideration, combinations of fibrous ingredient, including the The tribological tests are conducted on a Krauss type friction
hazardous chrysotile asbestos fibre are used for incorporation in machine which is computer-controlled along with data acquisition
materials to match the performance of traditional. Furthermore, capabilities as shown in Fig. 1. The rotor disc is connected to a
research based on incorporation of chrysotile asbestos nanotubes shaft through an interchangeable flange that engenders a moment
and carbon nanotubes or clay nanotubes like halloysites reveals of inertia of 2.5 kg-m2. A pair of brake pads (area¼30 cm2) is
that the carbon nanotube or clay nanotubes like halloysites has press-fit into a pressure-actuated sliding caliper assembly against
opposite sides of the rotor disc at a mean contact radius of 95 mm.
Table 1 The contact pressure is maintained at 2 MPa by adjusting load on
Details of composite composition and designation. the brake pads. The frictional force is quantified with the avail-
ability of a load cell mounted on the frame carrying the caliper pad
Composition PF BaSO4 Kevlar Lapinus Graphite MWCNT Nanoclay
(wt%) Resin
assembly, whereas the rise in temperature of the rotor disc is
quantified by using a thermocouple for every cycle of braking in a
FC-1 15 50 5 10 5 0 0 synchronized manner. In order to evaluate the tribological perfor-
FC-2 15 50 5 10 2.50 2.50 0 mance of the brake friction material, a standard test procedure
FC-3 15 50 5 10 2.50 0 2.50
(PVW-3212) as per the European norms conforming to ECE R-90
FC-4 15 50 5 10 2.50 1.25 1.25
(European Commission for Energy Reguation-90) is adopted
Table 2
Processing details while fabricating the friction composites.
Procedure Conditions
Sequential mixing A plough type of shear mixture with feeder and chopper speeds fixed at 300 and 3000 rpm, respectively, are used for mixing. Mixing sequence: For
FC-1 phenolic resin mixed with Kevlar and lapinus fibres for 5 min, thereafter Graphite and Barite are added for another 5 min. For FC-2/FC-3/FC-4
nano-filler (MWCNT/nanoclay) and phenolic resin are mixed for 20 min, thereafter Kevlar and lapinus fibres are added for 5 min and lastly Graphite
and Barite are added for another 5 min
Compression 155 1C, Compression pressure of 15 MPa, Curing time ¼10 min with four intermittent breathings to expel volatiles
moulding
Post-curing 150 1C, 5 h for relieving any residual stresses developed during the compression molding cycle
12 T. Singh et al. / Wear 324-325 (2015) 10–16
Fig. 1. Schematic of Krauss testing machine for friction and wear testing of brake friction materials. (1) Machine bed (2) compressed air supply (3) bearings movable (4) air
inlet (5) bearings (6) option SH 2.5 kg-m2 (7) emergency stop option (8) bearings (9) options SH 5 kg-m2 (10) flywheel connected to DC motor housing through a belt drive
with clutch option actuated by a generator.
min
dj Step VI: In this step, the overall preference value ðζ j Þ is
xij ¼ ; if j is the cost criteria ð2Þ determined with the help of the following equation:
dij
Δj
ζj ¼ ð6Þ
Step III: In this step, the mean of the normalized (χ j ) value of j ¼ 1 Δj
∑N
PDC j is determined by using the equation:
1 M Moreover, the total overall preference value of all the PDC
χj ¼ ∑ x ð3Þ
M i ¼ 1 ij should be one i.e. ∑N j ¼ 1 ζj ¼ 1
Step VII: In this step, the preference selection index ðϖ i Þ value
Step IV: In this step, preference variation value ðφj Þ for each for each alternative is determined by using the following
PDC is determined with the help of the following equation: equation:
M h i2
φj ¼ ∑ xij χ j ð4Þ N
i¼1 ϖ i ¼ ∑ xij ζ j ð7Þ
j¼1
Table 4
Description of the different performance defining criterions.
Coefficient of friction (m) PDC-1 Higher-the-better It is the average friction coefficient of cold, fade and recovery cycles.
Wear (g) PDC-2 Lower-the-better It is the progressive loss of the material from the brake pad surface during working.
Friction fade-% PDC-3 Lower-the-better %-Fade¼ mP mF =m 100, mF is the minimum coefficient of friction for the fade cycles taken
after 270 1C.
Friction recovery-% PDC-4 Higher-the-better %-Recovery ¼ mR =m 100, mR is the maximum coefficient of friction for the recovery cycle
taken after 100 1C.
Stability coefficient (%) PDC-5 Higher-the-better It is the ratio of the coefficient of friction to the maximum friction i.e. μP/μmax
Variability coefficient (%) PDC-6 Lower-the-better It is the ratio of minimum friction to the maximum friction coefficient, i.e. μmin/μmax
Friction Fluctuation (μmax–μmin) PDC-7 Lower-the-better It is the difference between the maximum and minimum friction coefficient i.e. μmax–μmin
Disc temperature rise (DTR) (1C) PDC-8 Lower-the-better It is the maximum temperature rise of the disc due to the friction braking irrespective of the cycle.
14 T. Singh et al. / Wear 324-325 (2015) 10–16
PDC-2 (Wear)
0.25 5 due to its mild abrasive nature, hence maintaining higher frictional
response: consequently resulting in higher m and reduced wear
0.20 4
performance [29–31].
0.15 3
0.10 2
3.1.2. Effect of nano-filler on PDC-3 and PDC-4
0.05 1 Fig. 4 shows the influence of nano-filler on the PDC-3 (friction
fade-%) and PDC-4 (friction recovery-%) of the investigated friction
0.00 0
composites. The temporary loss of braking effectiveness at higher
FC-1 FC-2 FC-3 FC-4
temperature (usually 4300 1C) due to the loss of friction between
Composition
the sliding surfaces as a result of the frictional heat is known as
Fig. 3. Friction and wear performance as a function of composition.
0.35
0.6
60 160 0.30
Friction Fade-% 0.5
Friction Recovery -% 140 0.25
50
PDC-4 (Friction Recovery -%)
0.4
PDC-3 (Friction Fade -%)
120 0.20
0.3
40 0.15
100
0.2
0.10
30 80
0.1 0.05
60
20 0.0 0.00
FC-1 FC-2 FC-3 FC-4
40
Composition
10
20
Fig. 5. Stability coefficient and variability coefficient as a function of composition.
0 0
FC-1 FC-2 FC-3 FC-4
µmax-µmin
Composition
Temperature rise of the disc
0.45 700
Fig. 4. Friction fade-% and friction recovery-% as a function of composition.
PDC-8 (Temperature rise of the disc)
0.40
600
0.35
500
PDC-7 (µmax-µmin)
0.30
3. Results and discussion 400
0.25
Table 6
The normalized decision matrix.
Table 7
Preference variation, deviation in the preference variation and overall preference
values.
Composite designation Preference selection index ðϖ i Þ Ranking lowest variability coefficient. Such observations clearly reveal that
the combination of lapinus and Kevlar fibres with or without
FC-1 0.8598 2 MWCNT content contribute to increase the stability coefficient
FC-2 0.8430 3 whereas nanoclay inclusion in friction formulation contribute to
FC-3 0.8745 1
FC-4 0.8347 4
minimal variability coefficient.
normalized in the range of 0–1 by using Eq. (2) and the normalized Make-To-Order environment, considering order priority, J. Manuf. Syst. 32 (1)
decision matrix is given in Table 6. After normalization, preference (2013) 124–137.
[12] A.H. Vencheh, A. Mohamadghasemi, An integrated AHP-NLP methodology for
variation value ðφj Þ, deviation ðΔj Þ in the preference variation value facility layout design, J. Manuf. Syst. 32 (2013) 40–45.
and overall preference value ðζ j Þ are determined for each PDC by [13] S.J. Kim, K.S. Kim, H. Jang, Optimization of manufacturing parameters for a brake
using Eqs. (4)–(6) and given in Table 7. Finally, the preference lining using Taguchi method, J. Mater. Process. Technol. 136 (2003) 202–208.
[14] T. Kato, H. Soutome, Friction material design for brake pads using data base,
selection index ðϖ i Þ value for each alternative is determined by Tribol. Trans. 44 (1) (2001) 137–141.
using Eq. (7). The alternative with higher ϖ i value is chosen as the [15] B.K. Satapathy, J. Bijwe, Performance of friction materials based on variation in
best alternative. The optimal sequence of friction composite nature of organic fibers Part II: Optimization by balancing and ranking using
multiple criteria decision model (MCDM), Wear 257 (2004) 585–589.
ranking is FC-3 4FC-1 4FC-2 4FC-4, respectively. The results are [16] Y. Zhao, Y. Lu, M.A. Wright, Sensitivity series and friction surface analysis of
shown in Table 8 and depicted in Fig. 7. From this analysis, it is non-metallic friction materials, Mater. Des. 27 (2006) 833–838.
observed that nanoclay filled friction composite shows the optimal [17] B.K. Satapathy, A. Majumdar, B.S. Tomar, Optimal design of flyash filled
composite friction materials using combined analytical hierarchy process
performance.
and technique for order preference by similarity to ideal solutions approach,
Mater. Des. 31 (2010) 1937–1944.
[18] Z. Zhu, L. Xu, G. Chen, Y. Li, Optimization on tribological properties of aramid
4. Conclusions fiber and CaSO4 whisker reinforced non-metallic friction material with
analytic hierarchy process and preference ranking organization method for
enrichment evaluations, Mater. Des. 31 (2010) 551–555.
In the present study, optimization of tribo-performance for brake [19] T. Singh, A. Patnaik, B.K. Satapathy, M. Kumar, Performance analysis of organic
friction material with and without nano filler content was carried out friction composite materials based on carbon nanotubes–organic–inorganic
successfully. MWCNT content has led to higher coefficient of friction, fibrous reinforcement using hybrid AHP-FTOPSIS approach (An International
Journal), Compos.: Mech. Comput. Appl. 3 (3) (2012) 189–214.
higher stability coefficient with least friction fluctuations but nano- [20] T. Singh, A. Patnaik, B.K. Satapathy, Development and optimization of hybrid
clay proved to impart highest wear resistance. The fade performance friction materials consisting of nanoclay and carbon nanotubes by using
of these friction composites has been found to be highly dependent analytical hierarchy process (AHP) and technique for order preference by
similarity to ideal solution (TOPSIS) under fuzzy atmosphere, Walailak J. Sci.
on the type of nano-filler and remain higher with MWCNT content.
Technol. 10 (4) (2013) 343–362.
A higher recovery response is registered for nanoclay filled friction [21] Y. Lu, A golden section approach to optimization of automotive friction
composites. The temperature rise of disc and friction variability materials, J. Mater. Sci. 38 (2003) 1081–1085.
coefficient remains highest for MWCNT filled friction composites. [22] L. Han, L. Huang, J. Zhang, Y. Lu, Optimization of ceramic friction materials,
Compos. Sci. Technol. 66 (2006) 2895–2906.
By applying PSI method, the ranking of tribo-performance of friction [23] K. Maniya, M.G. Bhatt, A selection of material using a novel type decision-
formulations could be obtained as FC-34FC-14FC-24FC-4, and making method: preference selection index method, Mater. Des. 31 (2010)
the formulation FC-3 having nanoclay content exhibits optimal 1785–1789.
[24] R. Attri, S. Grover, Application of preference selection index method for
properties. The overall study concludes that the type of nano filler decision making over the design stage of production system life cycle, J. King
influences the tribo-performance of brake friction formulation sig- Saud Univ.: Eng. Sci. (2013), http://dx.doi.org/10.1016/j.jksues.2013.06.003.
nificantly and PSI method was proved to be a rapid and strong [25] L.E. Murr, K.F. Soto, TEM comparison of chrysotile (asbestos) nanotube and
carbon nanotubes, J. Mater. Sci. Lett. 39 (2004) 4941–4946.
technique for assessment of the brake friction materials. [26] X. Shao, Q. Xue, W. Liu, M. Teng, H. Liu, X. Tao, Tribological behavior of
micrometer and nanometer-Al2O3-particle-filled poly(phthalazine ether sul-
References fone ketone) copolymer composites used as frictional materials, J. Appl.
Polym. Sci. 95 (5) (2005) 993–1001.
[27] R.C. Lam, Y.F. Chan, K. Maruo, Porous Friction Materials Comprising Nano-
[1] J. Bijwe, Composites as friction materials: recent developments in non- particles of Friction Modifying Materials, US patent, 2010, 7749562 B1.
asbestos fibre reinforced friction materials–a review, Polym. Compos. 18 (3) [28] Y. Liu, Z. Fan, H. Ma, Y. Tan, T. Qiao, Application of nano powdered rubber in
(1997) 378–396. friction materials, Wear 261 (2006) 225–229.
[2] T. Singh, Tribo-performance Evaluation of Fibre Reinforced and Nano-filled [29] H.J. Hwang, S.L. Jung, K.H. Cho, Y.J. Kim, H. Jang, Tribological performance of
Composite Friction Materials (Ph.D. Thesis), NIT Hamirpur, 2013. brake friction materials containing carbon nanotubes, Wear 268 (2010)
[3] N. Dadkar, B.S. Tomar, B.K. Satapathy, Evaluation of flyash-filled and aramid 519–525.
fibre reinforced hybrid polymer matrix composites (PMC) for friction braking [30] T. Singh, A. Patnaik, B.K. Satapathy, Effect of carbon nanotubes on tribo-
applications, Mater. Des. 30 (2009) 4369–4376. performance of brake friction materials, Am. Inst. Phys. (AIP) Conf. Proc. 1393
[4] A. Tiwari, H.S. Jaggi, R.K. Kachhap, B.K. Satapathy, S.N. Maiti, B.S. Tomar, (2011) 223–224.
Comparative performance assessment of cenosphere and barium sulphate [31] T. Singh, A. Patnaik, B.K. Satapathy, Friction braking performance of nanofilled
based friction composites, Wear 309 (2014) 259–268. hybrid fibre reinforced phenolic composites: influence of nanoclay and carbon
[5] R.K. Kachhap, B.K. Satapathy, Synergistic effect of tungsten disulfide and nanotubes, NANO 8 (3) (2013) 1–15.
cenosphere combination on braking performance of composite friction mate- [32] T. Singh, A. Patnaik, B.K. Satapathy, B.S. Tomar, M. Kumar, Effect of nanoclay
rials, Mater. Des. 56 (2014) 368–378. reinforcement on the friction braking performance of hybrid phenolic friction
[6] S.G. Amaren, D.S. Yawas, S.Y. Aku, Effect of periwinkles shell particle size on composites, J. Mater. Eng. Perform. 22 (3) (2013) 796–805.
the wear behavior of asbestos free brake pad, Results Phys. 3 (2013) 109–114. [33] S. Sharma, J. Bijwe, Mukesh Kumar, Comparison between nano- and micro-
[7] M. Kumar, J. Bijwe, Optimized selection of metallic fillers for best combination sized copper particles as fillers in NAO friction materials, Nanomater. Nano-
of performance properties of friction materials: a comprehensive study, Wear technol. 3 (2013) 1–9.
303 (2013) 569–583. [34] J. Bijwe, N. Aranganathan, S. Sharma, N. Dureja, R. Kumar, Nano-abrasives in
[8] D.M. Elzey, R. Vancheeswaran, S.W. Myers, R.G. McLellan, Intelligent selection friction materials-influence on tribological properties, Wear 296 (2012)
of materials for brake linings, in: SAE Proceedings of the 18th Annual Brake 693–701.
Colloquium and Engineering Display P-358, 2000, pp. 181–192. [35] Replacement Brake Lining Assemblies, PVW 3212; ECE Regulation no. 90,
[9] A. Jahan, M.Y. Ismail, S.M. Sapuan, F. Mustapha, Material screening and INTEREUROPE Regulations Limited, UN 31, March 1993, 1997.
choosing methods—a review, Mater. Des. 31 (2010) 696–705. [36] T. Singh, A. Patnaik, Performance assessment of lapinus-aramid based brake
[10] S. Gangwar, V. Kukshal, A. Patnaik, T. Singh, Computational optimization of pad hybrid phenolic composites in friction braking, Arch. Civ. Mech. Eng.
TiO2 filled A384 alloy composites in erosive environment, Int. J. Comput. (2014), http://dx.doi.org/10.1016/j.acme.2014.01.009.
Mater. Sci. Eng. 1 (3) (2012) 1–23. [37] B.K. Satapathy, J. Bijwe, Performance of friction materials based on variation in
[11] N. Manavizadeh, L. Tavakoli, M. Rabbani, F. Jolai, A multi-objective mixed- nature of organic fibres. Part I. Fade and recovery behavior, Wear 257 (2004)
model assembly line sequencing problem in order to minimize total costs in a 573–584.