Vol. 28, No. 16, (2019), pp. 783 - 791
Evaluation of Milled Chamaerops Fruit Shell for Production of Brake Friction Materials
Ahmed F. Mohamed1,2, Baraa O. Babakor1, Nouby M. Ghazaly3, Mohamed K.
Hassan1,4
1Mechanical Engineering Department, College of Engineering and Islamic Architecture, Umm Al- Qura University, Makkah, KSA
2Mechanical Engineering Department, Faculty of Engineering, Sohag University, Egypt
3Mechanical Engineering, Faculty of Engineering, South Valley University, Qena-83523, Egypt
4Production Engineering &Design Dept., Faculty of engineering, Minia University
Abstract
Brake pads are high consumable spare parts, so it must make brake pads of environmental materials which are available, cheap, safety and having properties such as; Friction Level. Brake pedal effort should be limit by elevation the coefficient of friction, Resistance to Oil and hydrophobic Contamination, Resistance to Wear, stable in Heat, Resistance to the Intensity of Pressure and Resistance to Moisture Sensitivity, Resistance to Wear, stable in Heat, Resistance to Oil and Water Contamination, Resistance to the Intensity of Pressure and Resistance to Moisture Sensitivity. The former Model of Brake Pads made of mixed of milled Chamaerops fruit shell, milled Nano white sandstone and quarried iron oxide in Nano size. An investigation by Fourier transform Infra-red spectrometry and scanning electron microscope required to test the formed disc of Brake Pads. Examined samples are safety (Eco-friendly) because it is free asbestos.
The results show that examined samples are: high limit friction, resistance to oil and water absorption, highest tensile and compression properties, and thermal stability.
Choice Chamaerops for making brake due to several reasons; (1) Chamaerops excelsa peroxidases (CEP) are very stable enzymes, which has a high ph. and thermal stability. (2) Chamaerops applied as a Corrosion Inhibitor for Steel. (3) Chamaerops contains tocols, carotenoids, and chlorophyll impart significant stability against oxidative deterioration.
Keywords: Chamaerops fruit shell, Brake Pads, Infra-red spectrometry, scanning electron microscope
1.
IntroductionRecently, natural composite materials have become very important due to there are free of pollutions. There have been used in many industries such as automotive, aerospace, building and construction, and furniture industries. There are several types of natural fiber composites, especially plant-based fiber composites, have been developed.
However, natural composites suffer from weak interfacial bonding. The solving of these problem is the treating by various established methods such as alkali treatment and compatibilizing agent [1].
Biomasses are the second abundant resources for the production of materials and commodity chemicals after the rocks. Trees, plants and the food waste biomass can be considered as potential raw materials for the production of several lignocellulosic functional composites. They recommended that automotive brake pads manufactured by Agro-biomass friction materials [2], agricultural residue-based composites are an excellent candidate for the safe and green future [3].
The most tested manufactures brake pads of environmental materials interested in tow points; the friction coefficient and ecofriendly (free asbestos) such as; [4]. Brake pads
developed by replacement of asbestos-free friction lining material by palm kernel shell.
The lining of brake pads depends on applied pressure, sliding speed and temperature.
Morphology of the debris of brake pads should be observed by scanning electron microscope(SEM) [5]. The investigation of the generated particles during brake dynamometer simulations by SEM to determine the types of particles [6]. Replacement asbestos by bagasse conclude that bagasse is effectively alternative in brake pad manufacture for asbestos [7]. Using Nano technology and transmission electron microscope used to evaluate of brake pads [8] [9] [10].
Brake pads manufactured by using Periwinkle Shell as healthy safety materials [11]. The replacement of asbestos by periwinkle shell particles in brake pads, made of milled of periwinkle shell particles at 125 μm is more suitable than commercial brake pad [12]. Asbestos in the brake pads manufacture replaced by banana peels [13]. Brake pads developed by manufactured of Maize Husks [14]., they conclude that brake pads of maize husks are more suitable ecofriendly than asbestos. They developed the brake pads using Pulverized Cocoa Beans Shells Filler. The developed Cocoa Beans Shells (CBS) of brake pads investigated by determining its mechanical and physical properties. Based on properties like coefficient of friction, water absorption, oil absorption, compressive strength, thermal conductivity, and tensile strength. CBS is without any known health implication as eco-friendly product. Composite organic materials (coconut fiber, abrasive materials and solid lubricant using powder metallurgy) used to make brake pads intended for small and medium vehicles. The factors influence the achievement of superior physical and mechanical characteristics for the composite materials produced are the type of components chosen in the recipes, the optimization of the proportion of the components and the parameters of the sintering technology the value of friction [15].
Stable peroxidases refer to their great potentiality for different applications of biotechnology. Peroxidase formed by Chamaerops excelsa palm tree which characterized by a thermal stability [16]. The extract of Chamaerops Humilis L. Improves the electrochemical parameters by increasing the polarization resistance and ennobling the corrosion potential, and it may be considered as a good inhibitor for reinforcement steel in a carbonated concrete pore solution [17]. Chamaerops humilis var. Humilis seeds collected from palm trees impart significant stability against oxidative deterioration [18]. The peroxidase was extracted from the Chamaerops excelsa (CEP). Chamaerops excelsa peroxidases (CEP) are very stable enzymes, which has a high ph and thermal stability. Figure 1. “Three-dimensional representation of the X-ray crystal structure of CEP. A. A schematic diagram of CEP, with the helices shown in orange and labeled according to Patterson and Poulos (1995). There are also four sulfide bonds, displayed in stick and yellow, those ensure protein structure stabilization. The heme group (black stick) is located between the distal and proximal domains. B. Close-up views of distal and proximal calcium-binding sites, where the seven bonds that generate the coordination of the ions (green spheres) are represented with dashed black lines, and the residues responsible for this with sticks” after [19].
Vol. 28, No. 16, (2019), pp. 783 - 791
Figure 1 Three-dimensional representation of the X-ray crystal structure of CEP after [19]
2. Experiments
Experiment processes include material equipment, methodology, investigation, results and discussion.
2.1 Material / Equipment
The composite materials included; commercial milled Chamaerops fruit shell (filler), epoxy resin (binder-matrix), Nano hematite (reinforcement), Nano Talc (cooling) and Nano silicon oxide (abrasives) which milled from white sandstone by ball milling apparatus in physical nanomaterial lab. South valley university. Table 1 illustrates the weight percentages of materials.
Table 1 composition of the disc brake
Organic matter%
Silicon oxide
%
Epoxy
%
Hematite
%
Talc
%
20 15 40 15 10
The materials presented in Table 1 were subjected to the sintering process.
After homogenization of the mixture of materials was introduced into a mold which allows to making disc samples with 50 mm diameter, figure 2 show the manufactured disc. The mold-sample assembly is compressed on a hydraulic press with a force of 5 KN. Table 2 illustrates the Parameters of the sintering process.
Table 2. Parameters of the sintering process
Heating Cooling
Temperature Time In Oven In Air
0C min. Temperature
0C
Time min.
Temperature
0C
Time min.
180 360 100 240 35 600
Figure 2 the manufactured brake disc
2.2 laboratory investigation
Manufactured disc brake investigated laboratory by infra-red spectroscopy to illustrate the function groups and bindings, scanning electron microscope used to show face of disc before and after friction process.
2.2.1 Physical-mechanical characteristics of friction material
The samples obtained after friction did not raise any problem in extracting it from the mold and have satisfactory shape, structure and hardness. Table 3 illustrate the result of testing the physic mechanical characteristics of the friction material produced.
Table 3 the result of physical/ mechanical characteristics of the friction material produced.
Density (g cm -3)
Porosity in oil (%)
Hardness HRS Breaking force(N)
Compressive strength (N mm-2)
1.4 0.15 64 15808 39,02756
2.2.2 Tensile Strength Assessment
Four samples of the same composite materials had tested by tensile strength at mechanical lab. South valley university, table 4 presents results of samples and the average of tensile values. Average tensile strength of samples was compared with that of the conventional pad.
Table 4. Average tensile strength for four samples
samples Tensile stress (MPa)
Tensile strain (mm)
Average Modulus (MPa)
Average Load at break (N)
Average Extension
at break (m)
Sample 1
17.228 0.091 730.054 1012.005 0.007
Sample 215.748 0.082 698.950 970.845 0.006
Sample 314.084 0.074 634.127 947.053 0.006
Vol. 28, No. 16, (2019), pp. 783 - 791
Sample 4
13.981 0.066 621.784 904.066 0.006
average15.260 0.078 671.229 958.492 0.006
2.2.3 Thermal Conductivity Assessment
The thermal conductivity of specimen of four samples of manufactured brake, table 5 show the result of conductivity for four samples and the aver age.
Thermal conductivity may be attributed to interfacial bonding between filler particles and matrix.
Table 5 the result of physical/ mechanical characteristics of the friction material produced.
Thickness (mm) Diameter (mm) Thermal Conductivity, λ (W/mk)
Sample 1
5.85 45.1 0.3519
Sample 2
5.92 44.04 0.3342
Sample 3
6.19 39.81 0.2617
Sample 4
6.22 37.06 0.2204
average
6.05 41.503 0.2921
2.2.3 Infra-Red Spectroscopy (FT-IR)
Infra-Red Spectroscopy (FT-IR) used to illustrate the function groups and bindings, Infra-Red Spectroscopy (FT-IR) for sample investigated at central lab.
South valley university. Table 6 show wavenumbers and its type of vibration, wavenumber 3431.71 cm-1 refers to broad, concentration dependent, wavenumber 2925.48 cm-1 refers to C–H stretch, wavenumber 1733.69 cm-1 refers to C=O stretching vibration, wavenumber 1609.31 cm-1 refers to C=C stretching vibration;
A= heavy element, group with a heavy element directly attached to C=C ,
Table 6 wavenumbers and its type of vibration
Wavenumbers cm-1 Type of Vibration
3431.71
broad,concentration dependent
2925.48
C–H stretch 1733.69
C=O stretching vibration
1609.31
C=C stretching vibration; A=
heavy element,group with a heavy element directly attached to C=C
1509.03
C=C stretching vibration
1456.59
symetrical deformation vibration 1246.75
C-H rocking vibration
1183.11
CH3 rocking vibration
1036.55
CH3 rocking vibration
829.24
CH3-metal groups due CH2 rocking vibration
471.51
skeletal vibration, two bands
445.44
C-C skeleton vibration
wavenumber 1509.03 cm-1 refers to C=C stretching vibration, wavenumber 1456.59cm-1 refers to symmetrical deformation vibration, wavenumber 1246.75cm-1 refers to C-H rocking vibration, wavenumber 1183.11cm-1 refers to CH3 rocking vibration, wavenumber 1036.55cm-1 refers to CH3 rocking vibration, wavenumber 829.24cm-1 refers to CH3-metal groups due CH2 rocking vibration, wavenumber 471.51cm-1 refers to skeletal vibration, two bands, and wavenumber 445.44cm-1 refers to C-C skeleton vibration.
2.2.4 Scanning Electron Microscope (SEM)
Manufactured disc brake investigated before and after friction by Scanning Electron Microscope (SEM) to analyst properties of that purpose disc brake.
Scanning Electron Microscope (SEM) investigated at central lab. South valley university. Figure 3 shows different scale of SEM before friction process (A) solid form, (B) gradation surface, (C) integrated texture, (D) sand particles, (E) graded and solid texture, and (F)graded and solid surface.
Vol. 28, No. 16, (2019), pp. 783 - 791
Figure 3 different scale of SEM before friction process (A) solid form, (B) gradation surface, (C) integrated texture, (D) sand particles, (E) graded and
solid texture, and (F) graded and solid surface.
Figure 4 shows different scale of SEM after friction process (a), (b) steel texture, (c) organic fibers, (d) solid sand particles, (e) hold friction system, and (f) friction sand within composite texture.
Figure 4 shows different scale of SEM after friction process (a), (b) steel texture, (c) organic fibers, (d) solid sand particles, (e) hold friction system,
and (f) friction sand within composite texture.
3. Results and Discussion
The essential purpose of these study is manufacture a brake pads characterized by of environmental materials which are available, cheap, safety and having properties such as; Friction Level. The coefficient of friction shoul d be sufficiently high to limit brake pedal effort, Resistance to Oil and Water Contamination, Resistance to Wear, stable in Heat, Resistance to the Intensity of Pressure and Resistance to Moisture Sensitivity. So, the composite materials formed of environmental materials such as; Chamaerops fruit shell (filler), epoxy resin (binder-matrix), Nano hematite (reinforcement), Nano Talc (cooling) and Nano silicon oxide (abrasives), the properties of these materials must match with the characteristics of the brake pads.
The investigation results of friction particles by Infra-Red Spectroscopy (FT-IR) were give good indicators for improvement the properties of the brake pads such as; (1) CH3 rocking vibration; “Rocking is like the motion of a pendulum on a clock, but an atom is the pendulum and there are two instead of one” after [20], which is indicator to forcer bindings and more solid, (2) CH3-metal groups due CH2 rocking vibration, which is indicator for consolidation, and (3) cis- alkanes and branched alkanes which is indicator to hydrophobic properties.
Different scales of SEM before friction process show improvement in some properties such as; solid form, gradation surface, integrated texture, solid sand particles, graded and solid texture, and graded and solid surface, which are required for improvement of brake pads. Different scales of SEM after friction process show;
steel texture, forcer binding due to presence of organic fibers, solid sand particles (friction surface), hold friction system reduce friction process, and particles of quartz within composite texture which have good solid properties.
4. Conclusion
Using milled Chamaerops fruit shell for forming brake pads is favorite due Eco-friendly, free asbestos, thermal stability and stability against oxidative deterioration. Results and Discussion interpretation that; The investigation results of friction particles by Infra-Red Spectroscopy (FT-IR) were given good indicators for improving the properties of the brake pads such as; Forcer bindings and more solid, consolidation, and hydrophobic properties. Different scales of SEM before friction process show improvement in some properties such as; solid form, gradation surface, integrated texture, solid sand particles, graded and solid texture, and graded and solid surface, which are required for improvement of brake pads. Different scales of SEM after friction process show; steel texture, forcer binding due to presence of organic fibers, solid sand particles (friction surface), hold friction system reduce friction process, and particles of quartz within composite texture which have good solid properties.
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