Failure Analysis of Brake Panel on Automotive Braking System

Yoyok Winardi, Munaji Munaji


Abstract


 This paper presents the results of a failure analysis investigation conducted in the braking componentof motorcycle. One of the components is the brake panel. This component has been replaced in the non-authorized dealer. After used within 3 months, the brake panels broken during the braking process. The investigation involves several procedures and testing techniques, including: visual observation, chemical composition testing, fractography and hardness testing.  Based on the results of the chemical composition testing, the brake panels are made of aluminum alloy (Al-Si) series 4xxx. Fractography was performed in scanning electron microscopy (SEM) and optical microscopy (OM). Vickers hardness machine is used to test the hardness. The result of the observations indicate porosity along the fracture area. The result of the hardness testing shows that the distribution of hardness in different zones is very uniform. Based on the overall analysis, the failure of the brake panel caused by stress concentration. Porosity in the solid solutions of brake panel is the cause. The emergence of porosity was suspected an error during the casting process.

Keywords


brake panel; failure analysis; stress concentration

Full Text:

PDF

References


O. P. Singh, S. Mohan, K. V. Mangaraju, M. Jayamathy, and R. Babu, 2010,“Thermal seizures in automotive drum brakes,” Eng. Fail. Anal., vol. 17, no. 5, pp. 1155–1172.

C. Sharma and M. Dhingra,2015, “Braking Systems in Railway Vehicles,” Inter.Jour.Eng.Res.Tech.,vol. 4, pp. 206–211.

A. Kumar and R. Sabarish,2014, “Structural and Thermal Analysis of Brake Drum,” Middle-East Jour. Sci.Res.,vol. 20, no. 8, pp. 1012–1016.

M. Kushal and S. Sharma, 2015,“Optimization of Design of Brake Drum of Two Wheeler through Approach of Reverse Engineering by Using Ansys Software,” IOSR.Jour.Mech.Civ.Eng.,vol. 12, no. 4, pp. 70–75.

S. D. Oduro,2012, “Brake Failure and its Effect on Road Traffic Accident in Kumasi,” Inter.Jour.Sci.Tech.,vol. 1, no. 9, pp. 448–453.

T. Daems, S. Karinka, B. S. A, and E. Versonnen, 2016,“Manufacturing Process Defects of Automotive Brake Drums and Implementation of Poka- Yoke – A Case Study,” Inter.Jour.Inov.Res.Sci.Eng.Tech., pp. 893–903.

S.Nishida.1992. “Failure Analysis in Engineering Applications.” Oxford: Butterworth-Heinemann Ltd.

M.Warmuzek.2004.Aluminum-silicon casting alloys: an atlas of microfractographs. USA:ASM International.

J. Campbell.2011."Complete Casting Handbook Metal Casting Processes , and Design. Oxford:Elsevier Ltd.

W. D. Callister,1991, “Materials science and engineering: An introduction (2nd edition),” Mater. Des., vol. 12, no. 1, p. 59.

D. Dispinar and J. Campbell, 2011,“Porosity , hydrogen and bifilm content in Al alloy castings,” Mater. Sci. Eng. A, vol. 528, no. 10–11, pp. 3860–3865.

I. Serrano-munoz, J. Buffiere, C. Verdu, Y. Gaillard, P. Mu, and Y. Nadot,2016, “Influence of surface and internal casting defects on the fatigue behaviour of A357-T6 cast aluminium alloy,” Inter. Jour. Fat.,vol. 82, pp. 361–370.

Y. Ren, W. Ma, K. Wei, W. Yu, and Y. Dai, 2014,“Degassing of aluminum alloys via the electromagnetic directional solidi fi cation,” Vaccum, vol. 109, pp. 82–85.

H. Puga, J. Barbosa, N. Q. Tuan, and F. Silva,2014, “Effect of ultrasonic degassing on performance of Al-based components,” Trans. Nonferrous Met. Soc. China, vol. 24, no. 11, pp. 3459–3464.

R. Haghayeghi, H. Bahai, and P. Kapranos, 2012,“Effect of ultrasonic argon degassing on dissolved hydrogen in aluminium alloy,” Mater. Lett., vol. 82, pp. 230–232.

R. Haghayeghi and P. Kapranos,2014, “The effect of processing parameters on ultrasonic degassing ef fi ciency,” Mater. Lett., vol. 116, pp. 399–401.

D. G. Eskin, K. Al-helal, and I. Tzanakis,2015, “Journal of Materials Processing Technology Application of a plate sonotrode to ultrasonic degassing of aluminum melt : Acoustic measurements and feasibility study,” J. Mater. Process. Tech., vol. 222, pp. 148–154.

D. Dispinar, S. Akhtar, A. Nordmark, M. Di Sabatino, and L. Arnberg, 2010,“Degassing , hydrogen and porosity phenomena in A356,” Mater. Sci. Eng. A, vol. 527, no. 16–17, pp. 3719–3725.

A. Niklas, S. Orden, A. Bakedano, M. Silva, E. Nogués, and A. I. Fernández-calvo, 2016,“Materials Science & Engineering A Effect of solution heat treatment on gas porosity and mechanical properties in a die cast step test part manufactured with a new AlSi10MnMg ( Fe ) secondary alloy,” Mater. Sci. Eng. A, vol. 667, pp. 376–382.

X. Liu, Z. Zhang, W. Hu, Q. Le, L. Bao, J. Cui, and J. Jiang,2015, “Ultrasonics Sonochemistry Study on hydrogen removal of AZ91 alloys using ultrasonic argon degassing process,” Ultrason. - Sonochemistry, vol. 26, pp. 73–80.

L. Zhao, Y. Pan, H. Liao, and Q. Wang,2012, “Degassing of aluminum alloys during re-melting,” Mater. Lett., vol. 66, no. 1, pp. 328–331.

H. Ni, B. Sun, H. Jiang, and W. Ding, 2003,“Effects of rotating impeller degassing on microstructure and mechanical properties of the A356 scraps,” vol. 352, pp. 294–299.

ASTM E92.2004.“Standard Test Method for Vickers Hardness of Metallic Materials,” PA:ASTM International.




DOI: https://doi.org/10.22219/jemmme.v4i1.7092 | Abstract views : 67 | PDF views : 0

Refbacks

  • There are currently no refbacks.


Copyright (c) 2019 Munaji Munaji, Yoyok Winardi

Creative Commons License
This work is licensed under a Creative Commons Attribution-NonCommercial 4.0 International License.