新型低树脂基摩擦材料的研制及其优化设计
发布时间：2019-05-27 09:40
【摘要】：随着社会的进步和道路条件的改善,汽车的运行速度越来越快,人们对车辆的安全性、舒适性提出了更高的要求,对摩擦材料的要求不再仅仅是安全可靠,而是提出了低噪声、耐磨性好、刹车平稳、不伤盘及环保等更高的要求。截至2014年年底,我国机动车保有量达2.64亿辆,其中汽车1.54亿辆。刹车片作为汽车耗材,具有非常广阔的市场。针对高树脂含量的摩擦材料硬度高、易在磨损表面形成碳化膜、易产生噪声等问题,本文首次提出采用低树脂并配以少量丁腈胶粉来制备摩擦材料。针对半金属材料热导率高、容易伤盘的问题,本文提出采用混杂纤维,并采用少量金属纤维作为导热材料来研制摩擦材料。对研制的摩擦材料进行分析检测,寻找最优的配方组合以及工艺参数组合。本文首先采用正交试验法进行配方设计,采用定速试验机、洛氏硬度计和压缩试验机测定摩擦材料的摩擦磨损性能和机械性能,研究配方中各组分对摩擦磨损性能和机械性能的影响。结合模糊综合评价法选出最优配方,利用扫描电镜观察优选出的配方试样磨损后的表面形貌,以研究其磨损机理。研究表明：树脂对摩擦材料的硬度影响最大,鳞片石墨对摩擦系数影响最大,焦炭对磨损率影响最大。粘结剂含量较高的8号试样摩擦磨损过程中在摩擦表面生成硬度高且致密的碳化膜,与摩擦盘贴合性降低,出现振动现象。16号试样磨损表面结构疏松多孔,摩擦表面没有出现光亮的碳化膜,摩擦磨损过程中平稳无振动。因此低树脂是有利于减小摩擦材料在制动过程中的制动噪声。对优选出的配方再进行工艺参数的优化。采用正交试验表进行工艺参数设计,利用定速试验机、压缩试验机、扫描电镜等对试样进行检测,分析各工艺参数对摩擦材料性能的影响,筛选出最优工艺组合,并进行装车路试。研究表明：成形压力对摩擦材料硬度的影响最大,成形温度对摩擦系数和磨损率的影响最大。适当提高成形温度,不仅仅使成形时间和热处理时间得到了缩短,有利于生产率的提高,缩短了时间成本,而且性能也有一定的提高。装车路试过程中,紧急制动良好,没有出现明显的制动噪声和伤盘现象,磨损后刹车片表面气孔率高,无光亮碳化膜。因此低树脂和少金属的设计对减少制动噪声、热衰退、伤盘和导热率过高等现象是可行的。
[Abstract]:With the progress of society and the improvement of road conditions, the running speed of automobile is getting faster and faster. People put forward higher requirements for the safety and comfort of vehicles. The requirements for friction materials are no longer just safe and reliable, but low noise. Good wear resistance, stable brake, no damage to the disk and environmental protection and other higher requirements. By the end of 2014, the number of motor vehicles in China had reached 264 million, of which 154 million were cars. Brake pads, as automotive consumables, have a very broad market. In order to solve the problems of high resin content, such as high hardness, easy formation of carbide film on worn surface and noise, this paper proposes for the first time to prepare friction material with low resin and a small amount of nitrile rubber powder. In order to solve the problem of high thermal conductivity and easy to damage disk of semi-metallic materials, this paper proposes to use hybrid fiber and a small amount of metal fiber as thermal conductive material to develop friction material. The friction materials were analyzed and tested, and the optimal formula combination and process parameter combination were found. In this paper, the formula design is carried out by orthogonal test method, and the friction and wear properties and mechanical properties of friction materials are measured by constant speed testing machine, Rockwell hardness tester and compression testing machine. The effects of various components on friction and wear properties and mechanical properties of the formula were studied. The optimal formula was selected by fuzzy comprehensive evaluation method, and the surface morphology of the selected formula sample was observed by scanning electron microscope (SEM) in order to study its wear mechanism. The results show that the resin has the greatest influence on the hardness of the friction material, the flake graphite has the greatest influence on the friction coefficient, and the coke has the greatest influence on the wear rate. During the friction and wear process of No. 8 specimen with high binder content, a high hardness and dense carbide film is formed on the friction surface, which decreases the adhesion with the friction disk and produces vibration phenomenon. The wear surface structure of No. 16 specimen is loose and porous. There is no bright carbide film on the friction surface, and there is no vibration in the process of friction and wear. Therefore, low resin is beneficial to reduce the braking noise of friction materials in braking process. The optimized formula was optimized and the process parameters were optimized. The orthogonal test table is used to design the process parameters, and the constant speed testing machine, compression testing machine and scanning electron microscope are used to detect the samples. The influence of each process parameter on the properties of friction materials is analyzed, and the optimal process combination is selected. And carry on the loading road test. The results show that the forming pressure has the greatest influence on the hardness of friction materials, and the forming temperature has the greatest influence on friction coefficient and wear rate. Properly increasing the forming temperature not only shortens the forming time and heat treatment time, which is beneficial to the improvement of productivity, shortens the time cost, but also improves the performance to a certain extent. In the process of loading road test, the emergency braking is good, there is no obvious braking noise and damage disk phenomenon, after wear, the surface porosity of brake pad is high, and there is no bright carbide film. Therefore, the design of low resin and less metal is feasible to reduce braking noise, thermal decay, high thermal conductivity and so on.
【学位授予单位】：重庆交通大学
【学位级别】：硕士
【学位授予年份】：2015
【分类号】：TB39
[Abstract]:With the progress of society and the improvement of road conditions, the running speed of automobile is getting faster and faster. People put forward higher requirements for the safety and comfort of vehicles. The requirements for friction materials are no longer just safe and reliable, but low noise. Good wear resistance, stable brake, no damage to the disk and environmental protection and other higher requirements. By the end of 2014, the number of motor vehicles in China had reached 264 million, of which 154 million were cars. Brake pads, as automotive consumables, have a very broad market. In order to solve the problems of high resin content, such as high hardness, easy formation of carbide film on worn surface and noise, this paper proposes for the first time to prepare friction material with low resin and a small amount of nitrile rubber powder. In order to solve the problem of high thermal conductivity and easy to damage disk of semi-metallic materials, this paper proposes to use hybrid fiber and a small amount of metal fiber as thermal conductive material to develop friction material. The friction materials were analyzed and tested, and the optimal formula combination and process parameter combination were found. In this paper, the formula design is carried out by orthogonal test method, and the friction and wear properties and mechanical properties of friction materials are measured by constant speed testing machine, Rockwell hardness tester and compression testing machine. The effects of various components on friction and wear properties and mechanical properties of the formula were studied. The optimal formula was selected by fuzzy comprehensive evaluation method, and the surface morphology of the selected formula sample was observed by scanning electron microscope (SEM) in order to study its wear mechanism. The results show that the resin has the greatest influence on the hardness of the friction material, the flake graphite has the greatest influence on the friction coefficient, and the coke has the greatest influence on the wear rate. During the friction and wear process of No. 8 specimen with high binder content, a high hardness and dense carbide film is formed on the friction surface, which decreases the adhesion with the friction disk and produces vibration phenomenon. The wear surface structure of No. 16 specimen is loose and porous. There is no bright carbide film on the friction surface, and there is no vibration in the process of friction and wear. Therefore, low resin is beneficial to reduce the braking noise of friction materials in braking process. The optimized formula was optimized and the process parameters were optimized. The orthogonal test table is used to design the process parameters, and the constant speed testing machine, compression testing machine and scanning electron microscope are used to detect the samples. The influence of each process parameter on the properties of friction materials is analyzed, and the optimal process combination is selected. And carry on the loading road test. The results show that the forming pressure has the greatest influence on the hardness of friction materials, and the forming temperature has the greatest influence on friction coefficient and wear rate. Properly increasing the forming temperature not only shortens the forming time and heat treatment time, which is beneficial to the improvement of productivity, shortens the time cost, but also improves the performance to a certain extent. In the process of loading road test, the emergency braking is good, there is no obvious braking noise and damage disk phenomenon, after wear, the surface porosity of brake pad is high, and there is no bright carbide film. Therefore, the design of low resin and less metal is feasible to reduce braking noise, thermal decay, high thermal conductivity and so on.
【学位授予单位】：重庆交通大学
【学位级别】：硕士
【学位授予年份】：2015
【分类号】：TB39
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