Metal Matrix Composites: Synthesis, Wear Characteristics, Machinability Study of MMC Brake Drum

94 Pages·2015·3.472 MB·English

by  Nanjappan Natarajan, Vijayan Krishnaraj, J. Paulo Davim (auth.)

SPRINGER BRIEFS IN APPLIED SCIENCES AND
TECHNOLOGY  MANUFACTURING AND SURFACE ENGINEERING
Nanjappan Natarajan
Vijayan Krishnaraj
J. Paulo Davim
Metal Matrix
Composites
Synthesis, Wear
Characteristics,
Machinability Study
of MMC Brake Drum
123
SpringerBriefs in Applied Sciences
and Technology
Manufacturing and Surface Engineering
Series editor
Joao Paulo Davim, Aveiro, Portugal
More information about this series at http://www.springer.com/series/10623
Nanjappan Natarajan Vijayan Krishnaraj
•
J. Paulo Davim
Metal Matrix Composites
Synthesis, Wear Characteristics,
Machinability Study of MMC Brake Drum
123
Nanjappan Natarajan J.Paulo Davim
Department of Mechanical Engineering Department of Mechanical Engineering
SriRanganathar Instituteof Engineering Universityof Aveiro
andTechnology Aveiro
Coimbatore Portugal
Tamil Nadu
India
Vijayan Krishnaraj
Department of ProductionEngineering
PSGCollege ofTechnology
Coimbatore
Tamil Nadu
India
ISSN 2191-530X ISSN 2191-5318 (electronic)
ISBN 978-3-319-02984-9 ISBN 978-3-319-02985-6 (eBook)
DOI 10.1007/978-3-319-02985-6
LibraryofCongressControlNumber:2014946431
SpringerChamHeidelbergNewYorkDordrechtLondon
(cid:2)TheAuthor(s)2015
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Acknowledgments
The authors Natarajan Nanjappn et al. would like to thank Elsevier Publisher for
granting permission for re use of the published materials. The authors Vijayan
Krishnaraj et al. would like to thank Nova Publisher for granting permission for
reuse of the published materials.
v
Contents
1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Metal Matrix Composites. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2 Advantages of MMC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3 Limitations of MMC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.4 Applications of Composites . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2 Literature Review . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1 Automotive Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2 Materials Used in Automotive Brake Drum . . . . . . . . . . . . . . . 7
2.2.1 Cast Iron . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.2.2 Compacted Graphite Iron. . . . . . . . . . . . . . . . . . . . . . . 7
2.2.3 Steel Shell Cast Iron Composite Brake Drum. . . . . . . . . 8
2.2.4 Steel Cage Reinforced Cast Iron Brake Drum. . . . . . . . . 9
2.2.5 Fly Ash Reinforced al MMC Brake Drum. . . . . . . . . . . 10
2.2.6 Silicon Carbide Reinforced Copper MMC . . . . . . . . . . . 11
2.2.7 Thixoformed Hypereutectic Aluminium Silicon Alloy. . . 11
2.2.8 Carbon/Carbon Composites . . . . . . . . . . . . . . . . . . . . . 13
2.3 Design and Optimization of Brake Drum . . . . . . . . . . . . . . . . . 13
2.4 Manufacturing of Metal Matrix Composite. . . . . . . . . . . . . . . . 14
2.5 Wear Analysis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.6 Testing of MMC for Brake Drum Applications. . . . . . . . . . . . . 17
2.7 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3 Synthesis of Metal Matrix Composites . . . . . . . . . . . . . . . . . . . . . 21
3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.1.1 Selection of Metal Matrix Composite . . . . . . . . . . . . . . 22
3.1.2 Selection of Reinforcement . . . . . . . . . . . . . . . . . . . . . 23
3.1.3 Properties of A356/SiCp MMC. . . . . . . . . . . . . . . . . . . 23
3.2 Manufacturing of MMC Brake Drum. . . . . . . . . . . . . . . . . . . . 24
3.2.1 Solid State Process . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
vii
viii Contents
3.2.2 Powder Consolidation . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.2.3 Diffusion Bonding. . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.2.4 Liquid State Process . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.2.5 Infiltration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.2.6 Dispersion Process . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.2.7 Spray Process. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.2.8 In Situ Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.2.9 Deposition Process . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.3 Fabrication of Dispersion Process Casting Set-up . . . . . . . . . . . 29
3.3.1 Melting Arrangement. . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.3.2 Feeding Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . 30
3.3.3 Fabrication of Stirrer Arrangement . . . . . . . . . . . . . . . . 30
3.4 Manufacturing of Al MMC Brake Drum . . . . . . . . . . . . . . . . . 31
3.4.1 Melting of Aluminum Alloy. . . . . . . . . . . . . . . . . . . . . 31
3.4.2 Preheating of Reinforcement Particle. . . . . . . . . . . . . . . 31
3.4.3 Stirring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.4.4 Casting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3.4.5 Machining of Casting . . . . . . . . . . . . . . . . . . . . . . . . . 32
3.5 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
4 Fabrication of Experimental Set-up and Testing. . . . . . . . . . . . . . 35
4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4.1.1 Power Transmission in Brake System . . . . . . . . . . . . . . 36
4.1.2 Thermal Analysis of Brake Drum. . . . . . . . . . . . . . . . . 37
4.2 Experimental Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
4.2.1 Fabrication of Brake Drum Test Rig. . . . . . . . . . . . . . . 38
4.3 Results and Discussions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.3.1 Dynamic Friction Coefficient. . . . . . . . . . . . . . . . . . . . 39
4.3.2 Continuous Braking. . . . . . . . . . . . . . . . . . . . . . . . . . . 45
4.3.3 Repeated Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
4.4 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
5 Wear Analysis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
5.2 Materials for Wear Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
5.2.1 Material for Wear Disc . . . . . . . . . . . . . . . . . . . . . . . . 52
5.2.2 Material for Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
5.3 Wear and Friction Coefficient. . . . . . . . . . . . . . . . . . . . . . . . . 53
5.3.1 Frictional Force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
5.3.2 Wear Coefficient of Disc Materials. . . . . . . . . . . . . . . . 54
5.3.3 Wear Coefficient of Lining Material. . . . . . . . . . . . . . . 54
5.4 Experimental Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Contents ix
5.5 Results and Discussions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
5.5.1 Wear of Cast Iron Sliding Against Friction Material. . . . 56
5.5.2 Wear of MMC Against Friction Material. . . . . . . . . . . . 56
5.5.3 Wear Comparison of Cast Iron and MMC . . . . . . . . . . . 57
5.5.4 Wear of Friction Material Against Cast Iron . . . . . . . . . 58
5.5.5 Wear of Friction Material Against MMC. . . . . . . . . . . . 59
5.5.6 Comparison of Wear in Friction Material. . . . . . . . . . . . 60
5.5.7 Frictional Force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
5.5.8 Friction Coefficient. . . . . . . . . . . . . . . . . . . . . . . . . . . 62
5.6 Optical Micrograph of Contact Surfaces. . . . . . . . . . . . . . . . . . 63
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
6 Machinability of Metal Matrix Composites. . . . . . . . . . . . . . . . . . 67
6.1 Experimental Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
6.1.1 Material Synthesizing . . . . . . . . . . . . . . . . . . . . . . . . . 68
6.1.2 Experimental Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . 70
6.2 Results and Discussion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
6.2.1 Response Surface Regression Analysis . . . . . . . . . . . . . 72
6.2.2 RS Model Analysis. . . . . . . . . . . . . . . . . . . . . . . . . . . 74
6.2.3 Prediction of Output Using ANN . . . . . . . . . . . . . . . . . 78
6.2.4 Chip Formation Mechanisms . . . . . . . . . . . . . . . . . . . . 79
6.2.5 Effect of Hyperlox Coating on Tool Wear. . . . . . . . . . . 81
6.3 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Symbols
a Deceleration (m/s2)
A Inside surface area of brake drum (m2)
A Area of the master cylinder (m2)
mcp
A Outer surface area of the drum (m2)
s
A Area of the wheel cylinder (m2)
wc
BF Brake factor
c Specific heat of brake drum (Nm/kg (cid:3)C)
d
c Specific heat of shoe (Nm/kg (cid:3)C)
s
D Outer diameter of brake drum (mm)
d Stopping distance (m)
d Minimum stopping distance (m)
c
E Modulus of Elasticity (GPa)
E Braking energy (Nm)
b
F Pedal force (N)
F Brake force at front wheel (N)
bf
F Brake force at rear wheel (N)
br
F Total brake force (N)
bt
F Normal force in the drum (N)
N
h Convective heat transfer coefficient (Nm/h (cid:3)C m2)
r
I Mass moment of inertia of rotating parts (kg-m2)
k Correction factor for rotating masses
k Thermal conductivity of brake drum (Nm/hm2 K)
d
k Thermal conductivity of shoe lining (Nm/hm2 K)
s
L Inner width of brake drum (mm)
L Total width of drum (mm)
1
m Maximum mass of the vehicle (kg)
N Speed of brake drums (rpm)
n Number of brake applications
a
p Brake line pressure (N/mm2)
P’’ Maximum brake power for one brake drum (Nm/s)
max
P Brake power absorbed (Nm/s)
b
xi