Sintered Brake Pads Failure in High-Energy Dissipation Braking Tests: A Post-Mortem Mechanical and Microstructural Analysis

Study on the Strength of the Brake Pad of a Freight Wagon under Uneven Loading in Operation

The paper highlights the results of determining the strength of the brake pad of a freight wagon under uneven loading in operation. The main reasons for the uneven loading on the pad have been found. A mathematical tool for determining the strength of the pad unevenly loaded has been proposed. In the study, the pad is considered to be a rod system loaded with concentrated forces and bending moments. Sensors have been used in order to detect the load state of the brake pads. These sensors have been defined in the simulation software, and they have been placed on the working surface of the pad in the area of its interaction with the wheel. The operation of these sensors was simulated in the simulation software package. The results of the calculation have shown that the stresses in the pad are about 21.1 MPa; thus, they exceed the permissible values by 29%. Therefore, considering the uneven loading of the pad in operation, the strength of the pad is not ensured. To test the obtained results, the strength of the pad was determined using the finite element method. The Coulomb criterion was used for the calculation. It was found that the maximum stresses in the pad were about 19 MPa. These stresses were 21% higher than permissible values and occurred in the back of the pad. The study has proven that the uneven loading on the brake pad in operation can cause their destruction during braking. This may also cause traffic accidents with freight trains during their movement. The results of this study will contribute to the theoretical developments and recommendations aimed at improving the brake system of a freight wagon and rail traffic safety. It is considered that the tensometric sensors will be applied in future experimental tests for comparison and verification of the achieved results from the simulation computations.

Temperature Influence on Brake Pad Friction Coefficient Modelisation

Brake pad linings are an essential part of the correct functioning of braking systems based on the use of pads and discs. Generally, the compounds used to make the gaskets are characterised by the use of over 20 sintered components, which allow friction coefficients that vary between 0.2 and 0.6 at temperatures up to 200 °C. In this work, a traditional compound was investigated under close-to-real conditions in order to evaluate the tribological behaviour at different temperatures. Finally, a model based on the proportionality between temperature increase and relative variation of the friction coefficient was proposed. From the experimental test, it was evident that the friction coefficient increased with the temperature, passing from 0.4 to 0.6 in the temperature range of 100 °C to 180 °C; however, a further temperature increment until 350 °C caused a reduction in the friction coefficient to 0.2. The proposed model was able to anticipate the abovementioned trend, especially at high temperatures.