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Contenido archivado el 2024-06-10

Process of manufacturing brake linings - 'but not limited to'- by the use of ultrasonic energy input

Objetivo



This proposal is prepared with the help of an Exploratory Award which include a Research Feasibility Study. Compaction processes for composite materials are widely used in the industry for the production of highly filled composites. A conventional process is compacting the composite material under high pressure and temperature. Such moulding of friction materials using heat and pressure in the traditional manner becomes increasingly inefficient. The energy used in the process is excessive and the pressure in the application is very high. This high pressure increase the costs of production of compaction presses extremely. This project introduce a total new system of energy transfer to the compaction processes for composite materials which decreases the energy consumption of production and increases the quality of products. As we could work out in the feasibility study, the new technology is capable to compact composite materials realizing the mentioned effects. The remaining risks are clear defined and therefore calculable. The new process is based on an ultrasonic power unit, which is generating the ultrasonic energy. This ultrasonic energy is leaded direct into the center of the compaction mould. The composite material in the mould will be compacted under pressure. The necessary pressure for the compaction process is under usage of the ultrasonic energy, significant lower than in conventional heated systems. Additional, the total electric energy consumption, compared with a conventional system is considerable lowered. Product quality, specifically for brake pads can be increased the important fading coefficient. The process have been tested under brake pad production, but it can be easily transferred to similar compaction processes. In a first step, an ultrasonic laboratory press will be designed and manufactured, which is necessary to study all process parameters and the influence of ultrasonic energy on product and mechanical equipment. Parallel, new recipes of composite material and glue, supporting the ultrasonic process by a maximum, will be developed. With the results of this study, in a second step an industrial designed ultrasonic press central unit, the so called ultrasonic prototype press, will be manufactured. By this prototype press, it will be possible to evaluate the quality of process and products. The industrial team necessary to successful execution of the project has been selected on the basis of a supply chain. It includes all manufacturer of basic elements of a brake pad press and the supplier of essential raw materials as well as the end user, a brake pad producer.

Ámbito científico (EuroSciVoc)

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Coordinador

Leinweber Mashinen Gmbh & Co KG
Aportación de la UE
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Dirección
8 - 10,Johann Giefing Strasse
2700 Wiener Neustadt
Austria

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Participantes (5)

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