【摘要】：隨著社會的進步和道路條件的改善,汽車的運行速度越來越快,人們對車輛的安全性、舒適性提出了更高的要求,對摩擦材料的要求不再僅僅是安全可靠,而是提出了低噪聲、耐磨性好、剎車平穩(wěn)、不傷盤及環(huán)保等更高的要求。截至2014年年底,我國機動車保有量達2.64億輛,其中汽車1.54億輛。剎車片作為汽車耗材,具有非常廣闊的市場。針對高樹脂含量的摩擦材料硬度高、易在磨損表面形成碳化膜、易產生噪聲等問題,本文首次提出采用低樹脂并配以少量丁腈膠粉來制備摩擦材料。針對半金屬材料熱導率高、容易傷盤的問題,本文提出采用混雜纖維,并采用少量金屬纖維作為導熱材料來研制摩擦材料。對研制的摩擦材料進行分析檢測,尋找最優(yōu)的配方組合以及工藝參數組合。本文首先采用正交試驗法進行配方設計,采用定速試驗機、洛氏硬度計和壓縮試驗機測定摩擦材料的摩擦磨損性能和機械性能,研究配方中各組分對摩擦磨損性能和機械性能的影響。結合模糊綜合評價法選出最優(yōu)配方,利用掃描電鏡觀察優(yōu)選出的配方試樣磨損后的表面形貌,以研究其磨損機理。研究表明：樹脂對摩擦材料的硬度影響最大,鱗片石墨對摩擦系數影響最大,焦炭對磨損率影響最大。粘結劑含量較高的8號試樣摩擦磨損過程中在摩擦表面生成硬度高且致密的碳化膜,與摩擦盤貼合性降低,出現振動現象。16號試樣磨損表面結構疏松多孔,摩擦表面沒有出現光亮的碳化膜,摩擦磨損過程中平穩(wěn)無振動。因此低樹脂是有利于減小摩擦材料在制動過程中的制動噪聲。對優(yōu)選出的配方再進行工藝參數的優(yōu)化。采用正交試驗表進行工藝參數設計,利用定速試驗機、壓縮試驗機、掃描電鏡等對試樣進行檢測,分析各工藝參數對摩擦材料性能的影響,篩選出最優(yōu)工藝組合,并進行裝車路試。研究表明：成形壓力對摩擦材料硬度的影響最大,成形溫度對摩擦系數和磨損率的影響最大。適當提高成形溫度,不僅僅使成形時間和熱處理時間得到了縮短,有利于生產率的提高,縮短了時間成本,而且性能也有一定的提高。裝車路試過程中,緊急制動良好,沒有出現明顯的制動噪聲和傷盤現象,磨損后剎車片表面氣孔率高,無光亮碳化膜。因此低樹脂和少金屬的設計對減少制動噪聲、熱衰退、傷盤和導熱率過高等現象是可行的。
[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.
【學位授予單位】：重慶交通大學
【學位級別】：碩士
【學位授予年份】：2015
【分類號】：TB39

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