Search Results (212)

To investigate the performance of skewed roller thrust bearings (SRTBs) in the no-back brake of horizontal stabilizer trim actuators (HSTAs), this study conducts systematic theoretical modelling, experimental validation, and numerical simulation focusing on torque and contact characteristic optimization. First, a theoretical model for resistance torque of the SRTB was established based on the kinematics and load behaviours, followed by a systematic investigation into the effects of roller centre position and skew angle on the bearing’s resistance torque. An experimental platform was built, and tests were carried out on the bearings to verify the results of the theoretical analysis. Subsequently, a tangent arc profile was applied to the rollers to mitigate stress concentration at their ends, and the influences of crown drop and straight segment length on roller contact stress were explored by finite element method. Finally, considering the actual operating conditions of no-back brake components, the effect of roller centre position on brake deformation and roller contact stress was studied. The results show that the resistance torque increases with both roller skew angle and centre position, but is insensitive to rotational speed. Roller contact stress first decreases rapidly and then increases gradually with crown drop, indicating the existence of an optimal crown drop value. This optimal value first decreases and then increases with increasing straight segment length, with the optimal parameters determined as 9 μm (crown drop) and 4 mm (straight segment length). In practical applications, asymmetric loading on the two sides of the ratchet disc causes uneven roller contact distribution and stress concentration. Adjusting the roller centre position to balance the deformation of the ratchet disc and rod shoulder can effectively reduce contact stress, with the optimal position being approximately 48 mm (slightly offset from the load centre of 49 mm). This study provides valuable insights for the optimal design of SRTBs and no-back brakes. Full article

In order to improve the wear resistance of titanium alloy and apply it to the high-speed train brake disc, TiNbZrV_x (x = 0, 0.2, 0.4, 0.6, 0.8) refractory medium-entropy alloy coatings were prepared on Ti-6Al-4V (TC4) substrate. The effect of V content on the microstructure, mechanical properties, and friction and wear properties of the coatings was studied. TiNbZrV_x coatings achieved good metallurgical bonding with the substrate, forming BCC and B2 phases and AlZr₃ intermetallic compound (IMC). From TiNbZr coating to TiNbZrV_0.8 coating, V promotes element segregation and new phase formation, which decreased the average grain size from 85.055 μm to 56.515 μm, increased the average hardness from 265.5 HV to 343.4 HV, and reduced the room temperature (RT) wear rate by 97.8%. However, the ductility of the coatings decreased from 15.7% to 5.8% because the grain boundary precipitates changed the dislocation arrangement, and the tensile fracture mode changed from ductile fracture to brittle fracture. Abrasive wear was the main wear mode at RT, and adhesive wear and oxidation wear were the main wear modes at elevated temperature. The COF at elevated temperature was lower than that at RT, because a large number of friction pair components were transferred to the coating surface at high temperature and were repeatedly rolled to form a dense film, which played a certain lubricating role. Full article

Brake squeal is an undesirable high-frequency noise caused by vibrations induced by friction in disc brake systems. The noise is strongly affected by temperature, as this influences the material properties of the friction pair and the dynamic behaviour of the brake components. This study investigates the effect of temperature changes on the squeal characteristics of a disc brake system under different operating conditions. Experiments are carried out using a laboratory-scale test setup comprising a rotating disc, pneumatically actuated callipers, and precise measurement equipment. A series of test combinations is performed by systematically varying three parameters: disc surface temperature (40, 55, 70, 85, 100 °C), brake pressure (4.0 bar), and disc rotational speed (50, 100, 150, 200 rpm). Acceleration data are acquired using an accelerometer mounted directly on the calliper, while sound pressure data are measured with a fixed-position microphone located 0.5 m from the disc surface. The collected data are analyzed in the time and frequency domain to identify squeal events and their dominant frequencies. The effect of temperature on brake squeal noise and vibration varies with operating conditions, showing different patterns at low and high disc speed at constant brake pressure. This highlights the importance of considering both thermal and mechanical factors together when addressing brake squeal. Full article

The transition to battery electric vehicles (BEVs) is enabling the significant redesign of key subsystems, including braking systems. This work presents a physics-based optimization framework for the preliminary design of a distributed electro-hydraulic brake-by-wire (DEHB) system tailored for electric vehicles. The DEHB system is modeled as a two-phase actuation process captured through a coupled electro-mechanical and hydraulic model: initial pad–disc clearance closure and subsequent pressure buildup. Sensitivity analysis is employed to identify critical design parameters, and a multi-objective genetic algorithm is used to minimize electrical power consumption, peak current, and maximum torque while satisfying performance constraints. The optimized configuration is benchmarked against commercially available solutions and validated against a multiphysics simulation, showing deviations below 8% for current and power. A dynamic analysis incorporating vehicle-level ABS logic demonstrates the improved performance and energy efficiency of the DEHB system during emergency braking, with a reduction of 50% in required power if compared to a non-optimized system. The results confirm the effectiveness of the proposed method for early-stage sizing and highlight the potential of DEHB architectures in future electric vehicle platforms. Full article

Currently, brake particle emissions from traffic are considered one of the dominant sources of particulate matter in the atmosphere. A recent question concerns the contribution to brake particles of Battery Electric Vehicles (BEVs). The present work assesses brake particle emissions by measurements of particle number (PN) and mass (PM) of three light-duty BEVs. One front disc brake of each vehicle has been enclosed in a customized casing with appropriate ventilation for forming the aerosol. All three BEVs have been measured on a two-axis chassis dynamometer. The BEV relying more on electric braking (some 68% of the braking energy was covered by electric braking) had the lowest brake PN emissions over the (emissions) WLTC at 6.4 × 10⁹ km⁻¹ per front brake. This was less than half with respect to the other BEV (where only 52% of the braking energy was electric). PM emissions of the two vehicles were similar at 0.93 mg/km for PM < 12 μm and 0.65 mg/km for PM < 2.5 μm, both for one front brake. However, one of the measured BEVs had extraordinarily high PN emissions, some 23 times higher than the lowest-emitting BEV. The difference in PM was not as high, but was some four times higher. Full article

Brake wear particles (BWPs) represent a major source of non-exhaust particulate matter from road traffic, contributing substantially to human exposure, particularly in urban environments. While traditionally associated with coarse and fine fractions, mounting evidence shows that brake systems emit large quantities of ultrafine particles (UFPs; <100 nm), which dominate number concentrations despite contributing little to mass. This paper synthesizes current knowledge on BWP formation mechanisms, physicochemical characteristics, environmental behavior, and toxicological effects, with a specific emphasis on UFPs. Mechanical friction and high-temperature degradation of pad and disc materials generate nanoscale primary particles that rapidly agglomerate yet retain ultrafine structural features. Reported real-world and laboratory number concentrations commonly range from 10³ to over 10⁶ particles/cm³, with diameters between 10 and 100 nm, rising sharply during intensive braking. Toxicological studies consistently demonstrate that UFP-rich and metal-laden BWPs, particularly those containing Fe, Cu, Mn, Cd, and Sb compounds, induce oxidative stress, inflammation, mitochondrial dysfunction, genotoxicity, and epithelial barrier disruption in human lung and immune cells. Ecotoxicological studies further reveal adverse impacts across aquatic organisms, plants, soil invertebrates, and mammals, with evidence of environmental persistence and food-chain transfer. Despite these findings, current regulatory frameworks address only the mass of particulate matter from brakes and omit UFP number-based limits, leaving a major gap in emission control. Full article

The design and construction of a racing car often involve determining the optimal technological solution and designing the subassemblies, taking into account the required specifications. The case presented in this paper details improvements to the fixture layout of a braking system using a floating disc, starting from the use of calipers and brake pads that are already available on the market, and the design, modeling, and manufacture of an optimal brake disc for car requirements. Based on their accumulated experience, the authors identified the cause of vibrations under certain braking conditions, as well as the causes leading to mechanical fatigue of the braking system components. Following the simulations, the design of the floating brake disc was improved and subsequently, a car equipped with this new type of brake disc was tested to analyze the behavior of the braking system. The results showed an improvement in the maneuverability of the car, a slower deterioration of the components of the braking system and a temperature reduction in the components during operation on the circuit. Full article

Brake particulate matter (PM) represents a significant portion of the non-exhaust related soot emissions from all forms of transport, posing significant environmental and health concerns. Euro 7 standards only regulate road automotive emissions, while no regulation covers train transportation. This study compares two brake PM samples from rail and automotive applications. Rail brake PM was generated from composite brake pads subjected to real-world urban rapid transit braking conditions, while automotive brake PM was generated using ECE brake pads and discs under World Harmonized Light-Duty Test Cycle (WLTC) conditions. Transmission electron microscopy (TEM) and energy-dispersive X-ray (EDX) analyses were performed to assess PM morphology and composition. Both samples showed PM in coarse (10–2.5 µm), fine (2.5–0.1 µm), and ultrafine (<0.1 µm) size ranges, with angular flakes in automotive PM and rounded particles in rail PM. The rail PM exhibited a uniform size distribution, with a mean Feret diameter of 1 µm. In contrast, the automotive PM shifted toward larger particles, with ultrafine PM representing only 4% of the population. Excluding carbon and oxygen, automotive PM was dominated by iron (6 at.%) and magnesium (1 at.%). Rail PM showed lower iron (0.6 at.%) and higher aluminium (0.7 at.%) and calcium (0.8 at.%), with a broader non-C/O composition. This study tackles source-specific PM features, thereby supporting safer and more efficient non-exhaust emissions regulations. Full article

Grey cast iron brake discs are widely used in automotive applications due to their excellent thermal and mechanical properties. However, stricter environmental regulations such as Euro 7 demand improved surface durability to reduce particulate emissions and corrosion-related failures. This study evaluates multilayer coatings fabricated by Laser Metal Deposition (LMD) as a potential solution. Two multi-layer systems were investigated: 316L + (316L + WC) and 316L + (430L + TiC), which were primarily reinforced with ceramic additives to increase wear resistance, with their influence on corrosion being critically evaluated. Electrochemical tests in 5 wt.% NaCl solution (DIN 17475) revealed that the 316L + (316L + WC) coating exhibited the lowest corrosion current density and most stable passive behavior, consistent with the inherent passivation of the austenitic 316L matrix. In contrast, the 316L + (430L + TiC) system showed localized corrosion associated with micro-galvanic interactions, despite the chemical stability of TiC particles. Post-corrosion SEM and EDS confirmed chromium depletion and chloride accumulation at corroded sites, while WC particles exhibited partial dissolution. These findings highlight that ceramic reinforcements do not inherently improve corrosion resistance and may introduce localized degradation mechanisms. Nevertheless, LMD-fabricated multilayer coatings demonstrate potential for extending brake disc service life, provided that matrix–reinforcement interactions are carefully optimized. Full article

Runout is a common failure of brake discs. The detection of this fault usually depends on the driver, as there is a vibration in the car and on the brake pedal. As Advanced Driver Assistant Systems are implemented and autonomous driving modes are available, braking is carried out by the car instead. Brake disc runout can cause longer braking distance, so it is essential to recognize and repair it. NVH measurements have been validated to be one of the solutions to detect the fault immediately without disassembling the brake unit. In this article, the previous vibration measurements are extended with other methods that can also be used for fault detection. Brake fluid pressure measurement and integration of the disc rotation angle sensor enable the detection of faults without additional sensors. The aim of the research is to design a measurement method that can be compared with previously validated measurements. Full article

Railway braking efficiency hinges on the thermomechanical conditions at the wheel-rail interface. Frictional heating during operation causes significant temperature fluctuations, directly impacting braking performance in rail vehicles. Evaluating these effects is important for developing infrastructure and components adapted to environmental conditions. Several studies have explored the influence of temperature on components such as the brake disc or the wheel; little attention has been paid to the thermal conditions of the rail itself. This paper examines the effect of rail temperature on the braking behavior and energy consumption of a railway vehicle. Using a 1:20 railway track, rail segments were subjected to four temperatures (28.5 °C, 40.0 °C, 49.9 °C, 71.0 °C) by heating with Nichrome wire, and tests were performed at three speeds (0.75, 1.00, and 1.30 m/s). The results show that higher rail temperatures improve wheel-rail adhesion up to an optimum point (40.0 °C), beyond which performance deteriorates. In contrast, tests at 71.0 °C showed reduced braking efficiency, despite lower electrical current peaks, indicating a non-linear thermal response. Full article

This study aims to develop a non-contact automated impact-acoustic measurement system (AIAMS) for real-time detection of manufacturing defects in automotive brake calipers, a key component of the Electric Parking Brake (EPB) system. Calipers hold brake pads in contact with discs, and defects caused by repeated loads and friction can lead to reduced braking performance and abnormal vibration and noise. To address this issue, an automated impact hammer and a microphone-based measurement system were designed and implemented. Feature extraction was performed using Fast Fourier Transform (FFT) and Principal Component Analysis (PCA), followed by defect classification through machine learning algorithms including Support Vector Machine (SVM), k-Nearest Neighbor (KNN), and Decision Tree (DT). Experiments were conducted on five normal and six defective caliper specimens, each subjected to 200 repeated measurements, yielding a total of 2200 datasets. Twelve statistical and spectral features were extracted, and PCA revealed that Shannon Entropy (SE) was the most discriminative feature. Based on SE-centric feature combinations, the SVM, KNN, and DT models achieved classification accuracies of at least 99.2%/97.5%, 98.8%/98.0%, and 99.2%/96.5% for normal and defective specimens, respectively. Furthermore, GUI-based software (version 1.0.0) was implemented to enable real-time defect identification and visualization. Field tests also demonstrated an average defect classification accuracy of over 95%, demonstrating its applicability as a real-time quality control system. Full article

The present contribution showcases the potential brake emission reduction with Cr₂O₃ (chromium oxide) and WC-CoCr (tungsten carbide–chromium–cobalt) rotor coatings, as realized in our joint public–private research consortium. Particulate matter (PM) emissions from automotive braking systems have been characterized using a pin-on-disc tribometer equipped with particle measurement devices: a CPC (Condensation Particle Counter), an APS (Aerodynamic Particle Sizer), an SMPS (Scanning Mobility Particle Sizer), and a PM_2.5 sampling unit. Brake pad samples made from the same low-steel friction material were tested against a grey flake cast iron disc and two types of custom coated discs: a Cr₂O₃-coated disc and a WC-CoCr-coated disc. The friction pairs were investigated at a constant contact pressure of 1.2 MPa while the sliding velocity varied during the test, starting with 25 sequences at 3.6 m/s, followed by 19 sequences at 6.1 m/s, and finishing with 6 sequences at 11.2 m/s. The test results show encouraging 64% to 84% reductions in particle number (PN) emissions between 4 nm and 3 µm and 84% to 95% reductions in mass emissions (PM_2.5) thanks to the respective coated discs. SEM-EDXS (Scanning Electron Microscopy and Energy Dispersive X-ray Spectroscopy) analyses show that the hardness and roughness of the discs, the chemical reactivity (oxidation), and the abrasiveness of the three friction pairs are parameters that might explain this reduction in emission. Full article

Grey cast iron brake discs with lamellar graphite (GJL) offer excellent strength and thermal conductivity but are prone to wear and dust emissions. To mitigate these issues, a multilayer coating was applied via Laser Metal Deposition (LMD), comprising a 316L stainless steel base layer and a WC-reinforced top layer. This study examines the microstructural evolution of the coatings under simulated thermomechanical and corrosive conditions using a brake shock corrosion test. Microstructural characterization was performed via Scanning Electron Microscopy (SEM) and Electron Backscatter Diffraction (EBSD), focusing on grain size, orientation, and texture before and after testing. EBSD analysis revealed significant grain coarsening, with sizes increasing from below 20 µm to 30–60 µm, and a shift toward <101> texture. Hardness measurements showed a reduction in the WC-reinforced layer from 478 HV to 432 HV and in the 316L base layer from 232 HV to 223 HV, confirming the influence of thermomechanical stress. SEM analysis revealed a transition from horizontal cracks—caused by residual stress during LMD—to vertical microcracks propagating from the substrate, activated by braking-induced loads. These findings provide insights into the microstructural response of LMD coatings under realistic service conditions and underscore the importance of grain boundary control in designing durable brake disc systems. Full article

This study focuses on the influence of different brake pad formulations on the emission of particulate matter coming from car braking systems. The brake particles were characterised using a pin-on-disc bench and some particle measuring devices such as CPC, APS, SMPS and a PM₁₀ sampling unit. Seven samples of brake pad materials of different compositions (1 NAO and 6 Low Steel) were tested against grey cast iron discs. The results presented in this work show differences in particle number concentration and PM₁₀ emission factor between the different friction materials tested. Three friction materials, LS04, LS06 and NAO01, reduce particle number emissions by up to 71% and PM₁₀ emissions by up to 57%. On the other hand, this reduction in particulate emissions goes along with a reduction of 20% to 27% in the coefficient of friction. The microscopic analyses carried out on the test parts (pins and discs) show differences between the most emissive and the least emissive friction pairs, which may explain the differences observed in particle emissions. Correlations between the emission of particles and the concentration of iron of the PM₁₀, as well as the steel fibre content in the formulas, were found. Full article