Document nkqrxjE93dpg5MN36dyqwejL2

V. D. Compton - 9- November 30, 1972 Friction Materials (B-1P0 R) 1. 397? Disc Brake Lining Development A cooperative program vas established vlth Component Engineering Office to develop nev disc brake lining formulations for use on proposed 3975 ^-vheel disc brake Pinto and Lincoln vehicles. Because of program changes and parts availability, dynamometer testing to date has been confined to the L - 1 (Lincoln Front Disc) brake. Variations of two basic formulations have been fabricated and tested by FAST, FM-<?, and brake dynamometer in an effort to find a brake lining which could satisfy both the nev Federal requirements (Docket 70-<?7 Notice 5) for Job 1, 1975 and yet be suitable for normal customer usage. For reference, tests were performed on Borg Warner's 71<?C-1, the best resin/asbestos composite from car tests, and Bendlx 7131N, the best semi-metallic lining from car tests. Borg Warner's lining was said to increase in effectiveness excessively, compared with rear drum brakes. The Bendix Semi-Met vas said to almost make the Federal requirements, but was a potential high warranty risk for light customer usage. One of our formulations vas superior to the Borg Warner material in most reinvent characteristics on the dynamometer simulation of the nev Federal requirement. Of particular significance was a tendency for decreasing brake effectiveness during the dynamometer procedure, offering some potential for a disc/drum system. The brake fluid displacement for this sample was high. After testing it vas found that the linings had not been machined flat on the back surface prior to riveting which could have resulted in excessive fluid displacement. Additional samples have been prepared of this formulation for testing on a disc/drum Lincoln. Variants of this formulation are being prepared for additional laboratory and dynamometer testing. Personnel: Anderson, Johnson Weintraub (Chemical Engineering Department) 8003 0251 -- PRODUCED BY FORD ___________ ! SCF-FORD-0944 W. D. Compton - 10 - November 30, 197^ ? Ford of Europe Brake Assistance Work on the Ford of Europe (FOE) pull. Judder, &nd diagnostic programs continues. The pull problem on TC and MB cars appears to be severe vith Ferodo linings and Leamington iron discs of different friction levels and vith Textar linings vhen discs from different foundries are mixed. Improved controls appear to have resolved the latter case. Also the Textar material passed the required performance tests to replace the Ferodo material, if needed. A cast iron specification change vas recommended by Process Research Department and Product Quality Office. Our lining composition and friction interface findings vere presented to FOE engineers and representatives of both vendors (see attached trip report). Technical discussions vith Ferodo personnel led to a program to identify the lining constituents vithin the Ferodo linings vbich cause these linings to be abnormally sensitive to different cast irons and typically to increase in friction between ambient and normal operating temperatures. Ferodo, through FOE, has supplied us 1<? variants of their base formulation for our laboratory evaluation. . Samples of brake discs, cast to the Process Research/Quality Control Office specifications, are being prepared by the Leamington Foundry. The brake Judder on FOE vehicles appears to be associated vith the Ferodo linings. Judder tendency is believed to be related to the pull tendency of this lining, so the experimental Ferodo samples will also be used for Judder evaluations. The rust formation and vet adhesion characteristics of these samples, when tested in conjunction vith production discs, also vill be investigated. Additional comments and recommendations on diagnostic equipment, tests, and personnel are being prepared. A limited diagnostic facility is now planned for FOE Dunton Research Center. Personnel: Anderson Weintraub (Chemical Engineering Department) 8003 0252 PRODUCED BY FORD V. D. Compton 11 November 30, 1972 3- Vet Clutches The compliance of automatic transmission clutch plates vas considered to be a factor in the generation of a driveline "clunk" upon shifting from Heutral to Drive or Reverse. A possible mechanism for this noise is as follows: the initial apply piston force generates enough torque to lock the clutch and/or separator plates from sliding on their splines; added clutch apply pressure then deflects the friction elements to a slight conical form, largely as a consequence of friction material compliance; upon completion of the clutch engagement the system dynamics results in a momentary drop of output torque; the reduced torque allows the clutch elements to slide on their splines, thereby releasing their stored energy; this elastic energy release produces an axial acceleration of the clutch drum assembly which impacts against a flat thrust vasher/spacer; the resultant impact produces the observed "post engagement clunk." Based on this hypothesis, the "clunk" could be eliminated, or reduced in severity, by extending the clutch application time, using a stlffer friction material, reducing spline drag, altering the metal thickness of the clutch elements, reducing the assembly endplay, and adding compliance to the thrust washer. Several of these have been tried by the Transmission Division with some success. We have studied the elastic behavior of the production clutch plates (SD1053 paper type material) ana several comparable materials. Both production samples of new SD1053 showed an unusual elastic response; stiff, soft, then stiff again. The material appeared to have an elastic collapse behavior above 60 psi facing pressure. This vas judged to be significant, since that was also the pressure above which the "clunk" occurred most frequently. Two used (1000 heavy duty clutch applications on a laboratory machine) samples of SD1053 were tested and found to behave elastically as most other paper-type friction materials. The 8003 0253 PRODUCED BY FORD V . C. Ccropton - 12 - November 30, 17^ change presumably resulted from surface vear and the mechanical action of hard usage. Problem used samples of SD1053 have been requested, but not yet received. Also it vas suggested to laboratory cycle the clutch plates from a vehicle vhich exhibits the "clunk" and retest in the same car to establish if the noise severity is significantly affected by heavy clutch plate usage and the associated changes of elastic response. Transmission Division has requested a duplicate of our elastic response test apparatus for their laboratory. Our design is being modified to accept all standard sizes of clutch plates, to be simpler to use, and to heat and cool more rapidly. Personnel: Anderson, Ting Reports SR*7<?-l?> H. Vu and C. M. Jones, Heat Transfer Analysis of Ford Hotary Engine Cooling Systems. John E. Mayer, Jr., Manager ffcchanical Research Department 80030234 PRODUCED BY FORD