Effect of cast-iron disc thickness on the reliability of tribological data from pin-on-disc test: Case study of brake friction materials

For braking system, rubbing between disc and brake pad generates heat, physical transformation on the contact, and activates many complex solicitations. Therefore, researchers used reduced scale testing to evaluate tribological and thermomechanical performance of friction composite. The pin-on-disc configuration of the tribometer is considered the better solution to reproduce these generated transformation and friction evolution. However, if the pin geometry is chospaden based on representative elementary volume (REV) approach, no research has investigated and justified the choice of the disc geometry and thickness. In this research work, an examination of the critical disc thickness is discussed, highlighting its substantial impact on the friction-wear behavior during brake application. For that, four disc thicknesses were tested, varying on thickness values (10, 15, 20, and 22 mm). Through this experiment, the friction coefficient evolution as function of braking numbers and sliding duration was studied while maintaining pressure and sliding velocity constant. Wear and temperature rise are identified for each disc thickness situation. A 3D thermal model is employed also to simulate the heat conduction and dissipation in brake system for various disc thickness. The temperature predictions are carried out using Ansys software. Experimental investigation presented the effect of the thickness on the friction stability, particularly at high temperature. Numerical results highlight the effect of reducing the thickness of the disc on the kinetic temperature rise through a rapid increase in disc temperature. The thickness modification used for the brake disc enhances the resulted thermal response and tribological brake pad performance, and consequently enhance the reliability of tribometer outcomes.