Materials Today: Proceedings xxx (xxxx) xxx
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Tribological and mechanical properties of AA6061 reinforced with SiC and graphite for automobile applications S. Padmavathy ⇑, R. Kamalakannan, A. Manikandan M.Kumarasamy College of Engineering, Karur, Tamilnadu, India
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Article history: Received 21 May 2019 Accepted 30 May 2019 Available online xxxx Keywords: Brake force Brake drum Friction Metal matrix composites Weight reduction
a b s t r a c t The main objective of this work to reduce the wear rate of the brake drum material used for braking purpose. Aluminium alloy of AA6061 is reinforced with the reinforcement materials of Silicon Carbide and Graphite in the various proportions to study the Tribological Properties and Mechanical properties for the application of Automobiles. After the fabrication of composite material for the brake drum is tested by using pin-on disc equipment for friction wear and hardness is measured by using Impact test. SEM analysis is carried out to view the image of mixing of Proportions evenly in the fabricated material. Ó 2019 Elsevier Ltd. All rights reserved. Peer-review under responsibility of the scientific committee of the International Conference on Recent Trends in Nanomaterials for Energy, Environmental and Engineering Applications.
1. Introduction A drum brake is a brake that usages pounding caused by a course action of shoes or pads that press outward against a turning chamber shaped part called a brake drum. The term drum brake for the most part suggests a brake in which shoes push on the internal surface of the drum. Right when shoes push apparently of the drum, it is regularly called an attach brake. Where the drum is pressed between two shoes, similar to a conventional plate brake, it is on occasion called a crush drum brake, however such brakes are for the most part remarkable. A related sort called a band brake uses a versatile belt or ‘‘band” wrapping around the outside of a drum. Remembering the ultimate objective to grow the capability of operation and better handiness, the brake drum material should satisfy the going with necessities Light weight, Good wear protection, Good warm conductivity, High quality to weight proportion, Free from rust, Easy to cast. Brake drum ought to be planned and created with such highlights to fulfill the above necessities. Rising fuel costs, shorter ceasing separation necessities, and the development in half breed vehicles all prompt an expanded request in lightweight vehicle segments. Changing business sector needs create inventive items.
⇑ Corresponding author.
One inventive item is a lightweight aluminum metal grid composite (MMC) brake drum that is generously lighter than the customary cast press item. The circle cast press with sharp surface is embedded by aluminum, gives a solid attachment aluminum and high warmth exchange to aluminum. The outcomes demonstrated that the heap and the sliding separation influence the wear rate of the amalgams and the wear rate expanded with expanding load for both the composites by [1]. The size and volume portions of the MMC fortifications, wear and scraping qualities and additionally elasticity were assessed [2]. The required material properties for motor applications are more prominent quality, light weight, controlled warm development, high warm conductivity and great wear protection [3]. Proposed aluminum based composites with bring down wear protection have better tribological properties [4]. Fortified practically reviewed aluminum network composite barrels and nonstrengthened aluminum chambers by centrifugal casting to get the microstructure and mechanical properties for assessment [5,7,8]. Aluminum composites are broadly utilized as a part of aviation and car enterprises because of their low thickness and great mechanical properties, better consumption protection and wear, low warm coefficient of development when contrasted with regular metals and alloys [6]. Development of Metal Matrix Composite for Brake Drum [9] Advanced Hybrid Materials Manufacturing & Characterization [10].
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[email protected] (S. Padmavathy). https://doi.org/10.1016/j.matpr.2019.05.354 2214-7853/Ó 2019 Elsevier Ltd. All rights reserved. Peer-review under responsibility of the scientific committee of the International Conference on Recent Trends in Nanomaterials for Energy, Environmental and Engineering Applications.
Please cite this article as: S. Padmavathy, R. Kamalakannan and A. Manikandan, Tribological and mechanical properties of AA6061 reinforced with SiC and graphite for automobile applications, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2019.05.354
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S. Padmavathy et al. / Materials Today: Proceedings xxx (xxxx) xxx Table 3 Ratio of sample 1.
2. Methodology STEP 1: Identification of Problem STEP 2: Composition of Materials in Different Proportions STEP 3: Casting of Materials STEP 4: Machining of Work Pieces STEP 5: Testing of friction & wear properties and Hardness and Impact strength STEP 6: Testing of SEM
Materials
1 2
Base material Reinforcement
3
Total
Composition (wt%) AA6061 SiC Gr
93% 4% 3% 100%
AA6061-T6 SiC Gr
92% 3% 4% 100%
Table 4 Ratio of sample 2.
All the Specimens are fabricated as per the ASTM Standards.
2.1. Problem identification The following effect of failures identified in the brake drum (Figs. 1 and 2).
S. No
S. No
Materials
1 2
Base material Reinforcement
3
Total
Composition (wt%)
Friction, wear failure Brake Drum. Thermal expansion of drums. Temperature rise while applying brake force Brake Drum weight. Corrosion of sliding places.
2.2. Experimental procedure By Using the Stir Casting Furnace all the Compositions are fabricated under certain Specifications as mentioned below (Tables 1 and 2). 2.2.1. Ratio of reinforcement materials See Tables 3 and 4.
Fig. 1. Wear failure.
3. Results and discussion 3.1. Friction & wear test SAMPLE SAMPLE SAMPLE SAMPLE
1 (2 kg load) (Table 5) (Figs. 3–5) 1 (3 Kg Load) (Figs. 6–8) 2 (2 kg Load) (Figs. 9–11) 2(3 kg Load) (Figs. 12–14)
3.2. Hardness test reading See Table 6. Fig. 2. Corrosion.
3.3. IZOD impact testing Specimen Detail
Table 1 Stir casting furnace specification. Specification Furnace temperature Stirrer speed Metal Melting Temp Reinforcement Pre heating Temp in °C Stirrer Timing
Length = 75 mm Breadth = 10 mm
900 °C 600 rpm 810 °C 600 °C 5 min
Formula Impact strength (I) = K/A
Table 2 Stir casting furnace condition. Work pieces
Furnace Temp °C
Metal Melting Temp °C
Stirrer Speed RPM
Stirrer Timing Min
Reinforcement Pre heating Temp °C
Sample 1 Sample 2
800 – 850 800 – 850
785 – 800 785 – 800
750 750
5 5
565–575 615–630
Please cite this article as: S. Padmavathy, R. Kamalakannan and A. Manikandan, Tribological and mechanical properties of AA6061 reinforced with SiC and graphite for automobile applications, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2019.05.354
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S. Padmavathy et al. / Materials Today: Proceedings xxx (xxxx) xxx Table 5 Friction & wear test readings. Work pieces
Track Radius
By Time in Min
By load in Kg
Speed in (RPM)
Frictional Force in (N)
Wear in (Micron)
Co-efficient of friction
Sample1
30
30
Sample2
30
30
2 3 2 3
1200 1250 1200 1250
11 13 10 12
109 111 76 49
0.37 0.43 0.48 0.40
Fig. 6. Wear. Fig. 3. Wear.
Fig. 4. Friction force.
Fig. 7. Friction force.
Fig. 5. Coefficient of friction. Fig. 8. Coefficient of friction.
Please cite this article as: S. Padmavathy, R. Kamalakannan and A. Manikandan, Tribological and mechanical properties of AA6061 reinforced with SiC and graphite for automobile applications, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2019.05.354
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S. Padmavathy et al. / Materials Today: Proceedings xxx (xxxx) xxx
Fig. 9. Wear. Fig. 12. Wear.
Fig. 10. Friction force. Fig. 13. Friction force.
Fig. 14. Coefficient of friction.
Fig. 11. Coefficient of friction.
K-Energy absorbed in J A-Area in mm2 Sample-I (Figs. 15 and 16) Sample-II (Figs. 17 and 18) (Table 7)
Table 6 Hardness test reading. S. No
Material
Hardness (BHN)
1 2
Sample 1 Sample 2
69.5 BHN 76.7 BHN
Please cite this article as: S. Padmavathy, R. Kamalakannan and A. Manikandan, Tribological and mechanical properties of AA6061 reinforced with SiC and graphite for automobile applications, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2019.05.354
S. Padmavathy et al. / Materials Today: Proceedings xxx (xxxx) xxx
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Fig. 19. SEM testing specimens. Fig. 15. Specimen before IZOD testing.
3.4. Scanning electron microscope (SEM) In this work, AA6061 brake drum was dispersed with different contents of reinforcement of SiC-(3%, 4%), Gr-(4%, 3%), is fabricated by using the stir casting technique. The result of hardness shows that the thermal, mechanical properties should be increased for adding the reinforcement of materials. Finally the SEM and hardness, wear & friction test report have been. The above discussion deals with testing their properties. The wear rate will be affected due to the applied load and the sliding distance of the material and it should be reduced (Figs. 19 and 20). The wear rate of the material will be increased if the load applied increases for all the alloys. Wear rate increases linearly at low loads and while increasing the sliding distance it will be increased. The size and shape of the aluminium alloy powders are depends on the cooling rate, flow rate of the cooling medium and the surface tension of aluminium alloy melt. The hardness value indicates the increase in hardness when the reinforcement percentage is increased linearly. Impact Strength also shows the increased strength. The SEM image of the second sample shows the uniform distribution of the base material and reinforcement material when compared with the first sample (Figs. 19–21).
Fig. 16. Specimen after IZOD testing.
Fig. 17. Specimen before IZOD testing.
4. Conclusion Aluminium Silicon alloy composite materials are widely used for a many number of applications like engineering structures, aerospace and marine application, sporting goods and so on. Here this work is mainly focused on Automobile application and especially for the brake drumased on our work we have found that the weight to strength ratio for Al alloy 6061 with Sic + Gr is better. The minimum wear rate and good strength has been obtained at AA6061 93% Sic 3%& Gr 4% ratio. This indicates that this composite material is having less weight with high Strength and it is very convenient to use in all the type of Practical applications.
Fig. 18. Specimen after IZOD testing.
Table 7 IZOD test results. Workpiece
Energy Absorbed (K) in J
Impact strength (I) in J/mm2
Sample-1 Sample-2
22 27
0.028 0.037
Please cite this article as: S. Padmavathy, R. Kamalakannan and A. Manikandan, Tribological and mechanical properties of AA6061 reinforced with SiC and graphite for automobile applications, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2019.05.354
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Fig. 20. SEM images sample 1.
Fig. 21. SEM Images Sample 2.
Acknowledgement Research work facilities are sponsored by the department of Mechanical Engineering. Thanks for providing the opportunity. References [1] Brijendra Gupta, Ashish Jashvantlal Modi, Review of automotive brake friction materials, Int. J. Adv. Eng. Res. Develop. 2 (2) (2015). [2] Harish K. Garg, Ketan Verma, Alakesh Manna, Rajesh Kumar, Hybrid metal matrix composites and further improvement in their machinability – a review, Int. J. Latest Res. Sci. Technol. 1 (1) (2012) 36–44. [3] M. Asif, K. Chandra, P.S. Misra, Development of aluminium based hybrid metal matrix composites for heavy duty applications, J. Minerals Mater. Characteriz. Eng. 10 (14) (2011) 1337–1344. [4] Michael Oluwatosin Bodunrin, Kenneth Kanayo Alaneme, Lesley Heath Chown, Aluminium matrix hybrid composites: a review of reinforcement philosophies:
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Please cite this article as: S. Padmavathy, R. Kamalakannan and A. Manikandan, Tribological and mechanical properties of AA6061 reinforced with SiC and graphite for automobile applications, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2019.05.354