Sharif Digital Repository

Composite friction materials used in the braking system of vehicles are composed of different ingredients (typically up to 20 materials). The overall physical properties of these products are determined by the type and percentage of the individual ingredients in the final composition and consequently, may differ from one product to another. This paper studies the cure characteristics of railroad composite brake blocks during compression molding. Numerical simulations using the control volume/finite element method (CV/FEM) are utilized to predict temperature fields and cure conversion during the process. As railroad brake blocks are normally thick-sectioned parts, a three-dimensional modeling... 

In compression resin transfer moulding (CRTM), resin flows inside a mould filled with fibrous reinforcement as a result of resin injection and mould compression. This process facilitates the resin flow through the fibrous reinforcement particularly for high fiber content parts. This paper presents the numerical simulation of filling process of CRTM in full three-dimensional domain. A mathematical model of three-dimensional resin flow inside the CRTM mould is presented. An effective elastic modulus is introduced for multi-layer preforms connecting the mould closing speed to deformation rate of individual layers. Control volume/finite element method (CV/FEM) is used and the numerical algorithm... 

In resin injection/compression molding (RI/CM), a preform often comprises layers of different fiber reinforcements. Each fiber reinforcement has unique through thickness and in-plane permeabilities as well as compressibility, creating a heterogeneous porous medium in the mold cavity. In the present article, numerical simulation is utilized to investigate the filling process of RI/CM in such a heterogeneous porous medium. The filling stage is simulated in a full three-dimensional space by using control volume/finite element method and based upon an appropriate filling algorithm. The flow in the open gap which may be present in the mold cavity is modeled by Darcy's law using an equivalent... 

The surface defluorination of Teflon in powdery form was performed using a chemical treatment. The reaction parameters including the reaction time, sodium, naphthalene concentrations were optimized using a Taguchi method to obtain maximum functionality on the particles surface. The surface functionality of the treated particles was analyzed by FTIR, energy dispersive X-ray analysis (EDX) and surface energy. Both treated (g-PTFE) and untreated (PTFE) Teflon were added to polyamide 66 (PA66) at various loadings up to 6 wt%. Mechanical, differential scanning calorimetry (DSC) and tribological analyses for different PA66/Teflon composites were carried out. The chemical treatment enhanced the... 

Effect of organoclay (OC) on the performance of styrene-butadiene rubber (SBR)/phenolic resin (PH) blend prepared by two-roll mill was investigated. The influence of OC content ranging between 2.5 and 30 phr on the performance of SBR/PH was investigated using X-ray diffraction (XRD), scanning electron microscopy (SEM), interfacial energy analysis, tensile, dynamic mechanical, swelling, cure rheometry and thermogravimetric analysis (TGA). It was found that the OC is mainly localized in the SBR phase of SBR/PH blend through the kinetically favored mechanism relevant to rubber chains. The results also demonstrated the positive role of PH on the dispersion of OC. Both PH and OC showed... 

The present study deals with the structure-property relationship of organoclay (OC) filled nanocomposites based on rubber blend comprising of nitrile-butadiene rubber (NBR) and phenolic resin (PH). To obtain a better insight into the characteristics of the NBR/PH/OC hybrid system, a simple model system consisting of NBR/OC nanocomposites is also taken into consideration. A series of NBR/OC and NBR/PH/OC nanocomposites containing a wide range of OC concentrations (2.5-30 phr) are prepared by using traditional open two-roll mill. Structural analysis performed by X-ray diffraction (XRD), scanning electron microscope (SEM), and transmission electron microscope (TEM) exhibits mixed exfoliated and... 

Various compositions of maleated ethylene-propylene-rubber (EPR-g-MA) toughened polyamide 6 without and with short glass fiber, i.e. 5-20 wt.% rubber and 5-20 wt.% fiber, are prepared using an industrial twin-screw extruder at different levels of feed rate (100-250 kg/h), screw speed (200-450 rpm) and barrel temperature (230-260 °C). Trial runs designed based on the Taguchi's orthogonal arrays are subjected to tensile, impact, scanning electron microscopy (SEM) and optical microscopy tests; and the results are used to perform the analysis of variance (ANOVA). It is shown that the rubber particle size decreases significantly by increasing the rubber content for the unreinforced blend. The... 

In the present investigation, mold filling process of resin injection/compression molding (RI/CM) is compared with resin transfer molding (RTM) for simple mold geometry. To do this, analytical solutions are obtained for RI/CM in unidirectional flow. Based on the analytical solutions, flow front progression and pressure distribution are compared with RTM at different fiber content. The results indicate that the RI/CM reduces the mold filling time significantly, particularly for composite parts with higher fiber content  

In the present article, cure kinetics of a commercially available composite friction material used in railroad vehicles is investigated using the rheometer measurements. Effect of ingredients of friction material compound, including rubber matrix, phenolic resin, and fillers, on overall cure kinetics of friction compound is also investigated by comparing the cure kinetics of friction material and rubber matrix compound. A phenomenological model and an Arrhenius-type equation is developed for cure kinetics and induction time of both friction material and rubber matrix. The parameters of the models are extracted from experimental data, using the rheometer at different temperatures and... 

Sedimentation of particles can undermine the uniformity of the product in the manufacture of the particle-filled composites. An adequate mathematical description of the sedimentation process could be helpful for providing necessary information concerning the dominant parameters and can give an insight for the process designer to prevent such an undesirable phenomenon in composite production. The present article deals with the mathematical modeling of settling particles during curing of polymer matrix composites. The sedimentation process is described by the mass conservation law for particles. Since the viscosity of the suspending polymer increases as a result of curing process, a new model... 

In the present article, the cure process of the railroad composite friction materials in the compression molding process is studied. Numerical simulation is used to analyze the process and a series of parametric studies are performed to reveal the effect of process parameters and material variables. The results show that the cure process and also the braking performance are governed by the thermophysical properties of the friction compound formulation, which are in tum dominated by the compound ingredients. It is suggested that such information can be used in designing of compound formulation to achieve a friction material with good frictional and processing properties