Technical Briefs

Grinding Micromechanisms of a Sintered Friction Material

[+] Author and Article Information
E. Bassoli

Department of Mechanical and Civil Engineering, University of Modena and Reggio Emilia, via Vignolese 905, Modena 41125, Italyelena.bassoli@unimore.it

E. Atzeni

Department of Manufacturing Systems and Economics, Politecnico di Torino, C.so Duca Abruzzi 24, Torino 10129, Italyeleonora.atzeni@polito.it

L. Iuliano

Department of Manufacturing Systems and Economics, Politecnico di Torino, C.so Duca Abruzzi 24, Torino 10129, Italyluca.iuliano@polito.it

J. Manuf. Sci. Eng 133(1), 014501 (Jan 24, 2011) (6 pages) doi:10.1115/1.4003336 History: Received February 04, 2010; Revised November 18, 2010; Published January 24, 2011; Online January 24, 2011

New brake-pad materials are inhomogeneous compounds with a variety of metallic and ceramic phases, whose interaction with the tool during the grinding operation is not fully understood. Yet, ground surface quality strongly influences the bedding-in phase. This research surveys how grinding operation affects the pad surface. The purpose is pursued by adopting an investigation protocol merging macroscopic outcomes with the study of chip-removal mechanisms and of the ground surface morphology in the microscale. A specific set of grinding tests is carried out on the friction material under different kinematic conditions. Macroscopic indicators of the process performances are measured and modeled. At a closer look, the ground surface shows a complex morphology that cannot be completely described by roughness values, but depends on how the various phases are distributed in the material and how they are affected by the tool during abrasion. A multiscale inspection procedure is proposed to assess the performances of a machining operation on complex materials, where the descriptive power of standard technological tests becomes inadequate.

Copyright © 2011 by American Society of Mechanical Engineers
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Figure 1

SEM image of the brake-pad rupture surface. Points 1–4, marked by signs “+,” refer to EDX spectra.

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Figure 2

Models for Ra,l and Ra,t

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Figure 3

Grayscale maps of surface depth measured by chromatic confocal microscopy: (a) V=34 m/s, fg=0.01 mm/grain rev and (b) V=15 m/s, fg=0.016 mm/grain rev

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Figure 4

BSE_A-B image of the ground surface: (a) V=34.05 m/s, fg=0.01 mm/grain rev and (b) V=15 m/s, fg=0.016 mm/grain rev

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Figure 5

SEM images of the ground surface (V=15 m/s, fg=0.016 mm/grain rev: (a) ground Al silicate with debris, irregular graphite surface, and emerging Zr silicate; (b) cracks in Zr silicate and in the metal matrix; and (c) emerging Zr silicate and matrix cracking and detach

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Figure 6

Schematic representation of the observed grinding mechanisms



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