Correlation of field and experimental test data of wear in heavy commercial vehicle brake liners

B. SURYA RAJAN; M. A. SAI BALAJI; C. VELMURUGAN

doi:10.1007/s40544-017-0138-x

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Research Article | Open Access

Correlation of field and experimental test data of wear in heavy commercial vehicle brake liners

B. SURYA RAJAN^¹(), M. A. SAI BALAJI^¹, C. VELMURUGAN^²

¹ Department of Mechanical Engineering, BS Abdur Rahman University, Chennai 600048, India

² Department of Mechanical Engineering, Panimalar Institute of Technology, Chennai 600048, India

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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℃, 250℃, and 300℃) 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.

Keywords

heavy commercial vehicle wear brake liner correlation factor inertia brake dynamometer friction

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Friction

Volume 5 Issue 1,
March 2017

Pages 56-65

DOI: 10.1007/s40544-017-0138-x

Cite this article:

RAJAN BS, BALAJI MAS, VELMURUGAN C. Correlation of field and experimental test data of wear in heavy commercial vehicle brake liners. Friction, 2017, 5(1): 56-65. https://doi.org/10.1007/s40544-017-0138-x

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10.1007/s40544-017-0138-x.T001Table 1Comparison of liner life expected through IBD wear test & the actual life of the liner L_Act.

Test carried on vehicles	Dynamometer(km)	City bus application(km)	High speed bus application (km)	High way trucks application (km)	Tipper application (km)
Observed liner life in km	97,232	28,000–32,000	15,000–20,000	185,000–235,000	10,000–12,000
Expected through IBD test, L_IBD	-----------------------------------------97,232 ----------------------------------
Average actual life, L_Act		30,000	17,500	210,000	11,000

10.1007/s40544-017-0138-x.T002Table 2Observations during the field trials.

Characteristics	City bus	High speed bus	Highway trucks	Tipper mining
Work done by brake (kJ/(t·km))	56.4	39.7	17.6	94.3
Number of brake actuation for 100 km distance travel	280	190	42	390
Number of brake actuation per km	2.8	1.9	0.42	3.9
Actual Distance travel for 6000 brake application, D_{Act 6000 Brake appl.}(km)	2143	3158	14286	1552
Deceleration rate in terms of g (average)	0.2	0.4	0.2	0.5
Temperature at interface (°C) (average of the observed values)	193	276	150	285

10.1007/s40544-017-0138-x.T003Table 3Correlation factor based on actual life (L_Act) and life based on field observation (L_FO) vs predicted life through IBD (L_IBD).

HCV	(A)L_IBD(km)	(B)L_FO(km)	(C)L_Act(km)	Correlation factor (CF)
HCV	(A)L_IBD(km)	(B)L_FO(km)	(C)L_Act(km)	CF_(A-B)	CF_(A-C)
CB		33,632	30,000	0.345	0.308
HSB	97,232	25,942	17,500	0.266	0.180
HWT	97,232	224,203	210,000	2.305	2.150
TL		12,749	11,000	0.131	0.113

(A) L_IBD = Expected life of liner based on dynamometer test as per industrial practice (km)

(B) L_FO = Expected life of liner based on the inputs from field observation (km)

10.1007/s40544-017-0138-x.T004Table 4Inputs to OEM based on field trial.

HCV/IBD	Number of brake actuations	Deceleration	Average speed	Avg. number of brake actuations for 1.5 kms	Deceleration (m/s²)	Field test temperature (℃)
CB	High	Low	Low	4.2	0.2 g	193
HSB	Low	High	High	2.85	0.4 g	276
HWT	Low	Low	Low	0.62	0.2 g	150
TL	High	High	Low-medium	5.85	0.5 g	285
IBD	High-low	High-low	High-low	1	0.3 g	200, 250 & 300