• Journal of Auto-vehicle Safety Association
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• v.13 no.3
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• pp.32-40
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• 2021

Composite material is very attractive because it has excellent mechanical property and is possible to lightweight due to the low density. However, composite material is less used compared to other systems in the chassis system because it is very hard to solve NVH problem when composite material is applied to vehicle. Especially, reducing squeal noise of composite brake system is essential to apply it to vehicle successfully. In this paper, we present a new solution to reduce squeal noise of composite brake system. To achieve this goal, we analyze main causes of noise using RCA (Root Cause Analysis), CA (Contradiction Analysis) and sequentially get IFR (Ideal Final Result) to solve the problem. Next, we define the function of composite brake system and derive control factors and noise factors. A variety of tests for factors like chamfer, slot, damping shim, underlayer of brake pad are done. In addition, we analyze level of contribution for control factors theoretically. Finally, we get the effective solution for reducing squeal noise.

• Journal of Auto-vehicle Safety Association
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• v.14 no.3
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• pp.41-47
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• 2022

Composite material is recently very important material for eco-friendly vehicles because of its excellent mechanical property and lightweight effect. So, many research results have been recently published for developing the composite material to apply vehicles. In this paper, new brake system is presented using composite material to response this situation. And advantages in terms of performance compared to competitive company will be discussed in depth to verify superiorities of the new composite brake. To do so, composite brake systems which have the same size as the competitive company to the same vehicle is applied. And superiorities through a variety of test results are presented. First, normal braking performances are compared with competitive company through braking effect, heat capacity and friction test, Second, circuit driving and high speed fade test are also verified with competitive company to confirm harsh braking performances for the new composite brake system. Finally, the effects of applying the composite brake to automobile industry like electric car are analyzed.

• Journal of Auto-vehicle Safety Association
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• v.14 no.2
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• pp.90-95
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• 2022

Composite material is widely used in the automotive industries because it has excellent mechanical properties and is possible to reduce weight due to the low density. However, there is a new obstacle to meet environment regulation like Cu less or Cu free regulation for the friction material. Although it is strongly demanded, there are few research results about that unfortunately. Unless this problem is not solved properly, it is impossible to apply composite brake system to vehicle. In this paper, a new eco-friendly friction material for composite brake system is represented to respond these regulations. To do this, friction characteristics between existing low steel friction material and new eco-friendly friction material are verified to secure performances for brake system such as effect characteristic, fade characteristic and wear characteristic. And composite brake gets the equivalent or better performance compared to a low steel friction material. Finally, this result contributes to the study of major principles for the development of eco-friendly friction material in the future.

• Journal of Auto-vehicle Safety Association
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• v.12 no.1
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• pp.26-32
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• 2020

The luxury car market has been steadily growing for the last 10 years and it might keep expanding in the future. Furthermore, it is expected to be a very competitive market because luxury cars are considred to reflect the technology level of motor companies. For this reason, it is very important for motor companies to improve performances of luxury vehicles. However, it takes years for the companies to increase the technology level for the high performances. In this paper, we aim to analyze the technologies for high quality brake perfomances through investigation of two luxury vehicle models and develop a new high performance brake system. First, we found out a variety of effective factors for the high performances. Second, we conducted the brake performance analysis to figure out the relationship between brake effort and brake feeling. Finally, we develped the new brake system using carbon ceramic composite materials to satisfy the high quality brake performances.

• Advances in aircraft and spacecraft science
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• v.7 no.2
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• pp.135-149
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• 2020

In the current paper, a generalization of the results of Zhao et al. (2008) on a new design of C/C composite multidisc brake system is presented. The purpose of this paper is to study the effect of thermal sensitivity of Carbon/Carbon (C/C) composite material on the temperature distributions, deformation, and stress during braking. In this regard, a transient temperature-displacement coupled analysis for C/C composite brake discs with frictional heat generation under simulated operating conditions is performed. An axisymmetric model for brake system is used for the finite element analysis according to the theory of energy transformation and transportation. The transient temperature distributions on the friction surfaces, deformation, and stress are obtained. To check the validity, the results are corroborated with other solutions available in the literature, wherever possible. The current study could be used as a guide in the initial design of a high performance multidisc brake system.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.23 no.7 s.166
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• pp.1104-1111
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• 1999

A brake pedal for the flight control system of the Korean primary trainer is developed using composite material. The development includes the structural design, stress analysis, manufacturing and the qualification tests. A FEM analysis is used for the structural design and stress analysis. Autoclaving process is used to fabricate the composite brake pedal. For the qualification tests, modular fixtures are developed and applied. It is shown that the composite brake pedal developed meets all the structural integrity requirements specified in the military specification for aircraft parts.

• Journal of Auto-vehicle Safety Association
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• v.11 no.1
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• pp.23-29
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• 2019

Recently, use of composite materials has been increasing for body structures and chassis parts in the car industry because of weight reduction effect and excellent mechanical thermal characteristics. However, application of composite materials in brake system is very difficult because it is hard to obtain enough brake performance due to low heat storage capacity of the composite materials. In this paper, we will present new carbon ceramic composite disc with high flow characteristic. To obtain this characteristic, new vent structures were designed by using ARIZ method and substance-field model analysis. The flow effect of these vent structures on the brake performance was verified by pugh matrix and cooling test. The test results show improvement of cooling performance up to $30^{\circ}C$. Finally, These results will improve brake the reliability of the brake performance for the high performance vehicles and electric vehicles.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.39 no.3
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• pp.283-289
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• 2015

In this study, the lightweight design of a brake bracket for a composite bogie was studied by considering two brake bracket models with thicknesses of 12t and 9t, respectively. For achieving this goal, finite element analysis and topology optimization were conducted. Firstly, the largest cross-sectional areas of the vertical and horizontal plates of the brake bracket were selected as the design variables. As the constraint, the Z-axis displacement of the brake bracket was increased by 2.5 units from the initial displacement value. The minimum volume fraction of the design regions was chosen as the objective function. The full model comprised a composite bogie frame and brackets attached together. However, to reduce the analysis time, 1D beam elements were used instead of the composite bogie frame by ensuring its equivalence with the full model. The result revealed that the weights of the 12t and 9t models of the brake bracket were reduced to 60 kg and 31 kg, respectively.

• Composites Research
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• v.13 no.6
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• pp.55-62
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• 2000

The strength test was done for the Carbon/Carbon rotor disk which is the critical part of a carbon/carbon brake system in an operating time. The loading fixture was designed for the static strength test of a single carbon/carbon brake disk using finite element analysis. To simulate the real dynamic system in a static condition, the friction surface of the rotor disk was fixed and static load was applied to the rotor slot in the circumferential direction. The described failure mechanism of the brake disk can be described as matrix cracking occurred first at the contact surface of the rotor slot, subsequent delamination from the cracked contact surface, and the final fracture at the notch of the rotor.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.26 no.4
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• pp.660-666
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• 2002

It has many variables and factors to design the friction materials for automotive brake pads. The purpose of this study is to develop the proper method for design of low-cost and to know friction characteristics of each raw materials. For the purpose of examining the effect of each major raw materials, we used the Taguchi L9(3$^4$)orthogonal matrix and 1/5 scale dynamo machine for evaluation of the friction characteristics of composite brake pads. By adapting the Taguchi method, it is easy to investigate the influence of each component in complicated composites friction materials. After analyzing the testing results by the Taguchi method, the effect of factors and levels influenced friction behavior was studied.