Objectives

Cast iron has been traditionally used as the braking disc material. In more recent years, however, composites, such as metal matrix composite (MMC) and carbon-carbon-composite (CCC) have also been in developing for vehicles (including aircraft) requiring higher braking performance. Most recently, a ceramic-carbon brake disc has been developing for high performance sports cars

Section A

- Outline the operation of the brake disc in the braking system.
- How do design & operational requirements influence fundamental material property requirements for the brake disc?
- Perform a material selection exercise using CES software highlighting the suitability of any two materials for this application.

Section B

- Review and discuss the characteristic microstructures and properties for one specific material FROM EACH of the four following classes of material:

- Cast iron

- Metal matrix composite

- Carbon-carbon composite

- Ceramics-carbon composite

Section C

- Justify and describe a chosen manufacturing route for brake discs made from each of the four specific materials reviewed in section B.

- Review how the selected manufacturing process affects microstructure and relevant properties.

Section D

- Review methods of Automation, (look at FMS, CIM methods in particular) assembly of the product, any components that may be standardised, describe the advantages and disadvantages of this process, incorporate lean methodologies (i.e. Poka Yoke and SMED). If production volume increases 4-fold, comment/recommend on what changes would be required to the manufacturing production provision to accommodate significant increases.

Section E

- Review how commercial and engineering requirements influence the suitability of each of the four materials chosen in part B for application as brake discs in their relevant markets / applications.