Research of friction materials applicable to the multi-disc brake concept

Abstract

This manuscript is focused on the investigation of tribological and thermodynamic parameters of the coated C45 steel substrate. A metallic coating of the WC-Cu base was applied on the C45 steel substrate using electro-spark deposition (ESD) coating technology. Three types of experimental WC-Cu coatings with different ratio of chemical elements were deposited on the surface of the C45 steel substrate using WC-Cu electrodes produced by the powder metallurgy route. Each sample had a different ratio of WC-Cu chemical elements. Subsequently, the friction factor (f) and the total wear of the sample were examined in a tribological laboratory. The objectively most suitable sample in terms of friction factor and service life was subjected to a braking simulation in Matlab® software together with three other commercial friction materials. A mathematical model of Newton's equations of motion was used to simulate braking. The last phase of the research was focused on the thermodynamic parameter during automatically guided vehicle (AGV) braking. The tribological results of tested coatings showed that the most suitable combination of chemical elements in the WC-Cu type ESD coating is the WC50–Cu50 ratio. The simulation of non-stationary heat conduction process in the brake system revealed that the most suitable thickness of the steel brake disc should be at least 8.2 mm. Ultimately, this research will help the designer to choose the right procedures for designing a multi-disc brake system.

Keywords

• ESD coating
• WC-Cu
• Friction materials
• AGV
• Simulation