Abstract
The correlation between the wear behavior of a heavy commercial vehicle (HCV) brake liner tested under controlled laboratory conditions and that in actual field conditions is investigated. A brake liner study for friction and wear is performed on an inertia brake dynamometer (IBD) at different temperatures (200 °C, 250 °C, and 300 °C) using 6000 brake actuations in a laboratory. The total wear loss of the brake liner at three different temperatures for 6000 brake actuations in IBD is found to be 1.12 mm. The actual field test is conducted on four different HCVs, namely, a city bus (CB), a high speed bus (HSB), a highway truck (HWT), and a tipper lorry (TL). These HCVs run at different terrain/traffic conditions and load conditions. When comparing the predicted life of the brake liner through the IBD test with the actual life of the brake liner in different HCVs, a vast difference is observed. Due to the large variation of liner life observed between the actual and predicted tests, an extensive field test is conducted. In the field test, the liner with identical formulation is fitted in the four types of HCVs. The predicted life of the liner using IBD is then correlated with the field test observation and a correlation factor is determined. Based on this correlation factor, the predicted life of the liner and the achieved life on the HCV are found to be fairly close. This study will be useful to design the friction material formulation and to predict the actual life of the brake liner for various HCVs.
Highlights
A brake liner designed/formulated for heavy commercial vehicle (HCV) finds application in different types of vehicles, such as passenger vehicles or load carriers
Brake liners used in various HCVs will have different life spans if they are used in different terrains, the formulation is the same
As per the original equipment manufacturers (OEMs) suggestion, the joint field trial is always recommended to obtain the average life of the friction material formulation
Summary
A brake liner designed/formulated for heavy commercial vehicle (HCV) finds application in different types of vehicles, such as passenger vehicles or load carriers. The root cause of the present study is due to large variations in brake liner wear life, observed between the experimental (IBD) and field trial (actual) of a typical formulation. In this investigation, the study of the frictional performance and wear life of a non-asbestos brake liner was conducted using IBD and compared with the actual life of a brake liner fitted in various HCVs operating over different terrain/traffic conditions and load conditions. Whenever a new brake liner formulation requires study of the wear life, the OEM cannot test it on various HCVs. this study can provide a few guidelines to predict the life of the brake liner for each HCV based on the IBD wear test results. The temperature of the drum surface is measured by a contact type temperature sensor located exactly in the middle of the inner rotating surface and the liner temperature is measured by the thermocouple placed on the brake liner 3 mm
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