Transport tekniğinde kullanılan kompozit fren balatalarının geliştirilmesi ve bulanık mantık metodu ile optimizasyonu
Development and fuzzy logic optimization of composite brake linings used in transportation
- Tez No: 949247
- Danışmanlar: DOÇ. DR. SERPİL KURT
- Tez Türü: Doktora
- Konular: Makine Mühendisliği, Mechanical Engineering
- Anahtar Kelimeler: Belirtilmemiş.
- Yıl: 2025
- Dil: Türkçe
- Üniversite: İstanbul Teknik Üniversitesi
- Enstitü: Lisansüstü Eğitim Enstitüsü
- Ana Bilim Dalı: Makine Mühendisliği Ana Bilim Dalı
- Bilim Dalı: Makine Mühendisliği Bilim Dalı
- Sayfa Sayısı: 140
Özet
Kompozit fren balataları bir çok bileşenden oluşan yapılardır. Bu bileşenler toz, partikül, fiber gibi formlarda olmaktadır. Ticari uygulamalarda balata bileşiminde kullanılan malzemeler çoğunlukla belli olup tedarikçi firmalar tarafından satışı yapılmaktadır. Tedarikçi firmalardan alınan benzer malzemeler farklı üretici, depolama, üretim parametreleri gibi bir çok sebepten dolayı değişkenlik göstermektedir. Bu değişiklikler istenen özelliklerde bir balata bileşimi belirlenmesini zorlayıcı ve pahalı yapmaktadır. Firmaların mevcut kompozit fren balatalarında performans iyileştirmesi, ekonomiklik, ticari rekabet benzeri sebepler ile arge çalışmaları yapmaları bir ihtiyaçtır. Üretimi yapılacak bir kompozit balatanın kullanım alanına göre değişen performans kriterleri değişkenlik göstermektedir. Bu sebeple firmalar çeşitli bileşen oranlarına sahip çok farklı kompozit balata üretimi yapmaktadırlar. Bunun yanında benzer performans kriterleri firmadan firmaya farklı olmaktadır. Bütün bu sebeplerden dolayı firmalar belli bir üretim reçetesi ve bileşen grubuna bağlı kalmakta, yasal veya ticari rekabet gibi zorlayıcı durumlar oluşmadıkça herhangi bir reçete değişikliğine gitmemektedirler. Bunun bir diğer sebebi de kompozit balata için yapılacak çalışmaların çok pahalı ve zahmetli olması sebebi ile bir çok firma için ekonomik olmaktan çok uzak olmasıdır. Bu sebeple firmalar ellerindeki mevcut reçeteleri ticari sır olarak gizlemekte, bundan dolayı da literatür çalışmaları sınırlı kalmaktadır. Bütün bu problemlerden dolayı attık ürünlerin mevcut reçetelere ilave edilmesi veya yeni reçetelerin oluşturulması konuları sınırlı kalmakta, bu konuda yapılan literatür çalışmaları değerlendirilememektedir. Endüstriyel atıkların kullanımını arttırmak, kompozit balata bileşenlerinin belirlenmesi için mevcut literatür verilerinin ekonomik kullanımı ve mevcut ticari firmaların arzu edilen arge faaliyetlerini yapılabilir hale getirmesi arzu edilen bir araç olarak kullanılmak üzere bulanık mantık metodunun kullanımı ele alınmıştır. Böylece firmaların mecut tecrübelerini literatür verileri ile destekleyerek daha hızlı ve ekonomik reçete çalışmaları yapabileceği bu tez kapsamında ele alınan çalışma ile sonuçlandırılacaktır. Bu tez kapsamında ekonomik değerlendirme ve çevryi koruma güdüsü ile ülkemiz termik santrai uçucu külleri ile atık araç lastik tozlarının kullanımı üzerinde durulmuştur. Çalışma sonucunda bu atıkların kullanıldığı ticari kullanıma uygun 4 tip balata reçetesi elde edilmiştir.
Özet (Çeviri)
Composite brake linings have a very wide range of applications and usage areas and there are many studies on the subject in the literature. Although these studies provide very important contributions to the literature, they are not clear enough when it comes to the manufacturing and use of inrubberrial brake linings. Composite brake linings are composites consisting of hundreds of different materials and containing up to 25 different constituents. The constituents are in the form of powder, particles, fibers, etc. In commercial applications, the materials used in the brake lining composites are usually known and sold by suppliers. Similar materials purchased from suppliers vary due to many reasons such as different manufacturers, storage, and manufacturing parameters. These changes make it difficult and expensive to determine a recipe with the desired properties. Manufacturers' recipes vary from company to company and mostly considered as trade secrets. The constituents known from literature or manufacturer's recipes give different results depending on the company and the quality of the constituents used. For effective braking performance, composite friction materials must have properties such as a balanced friction coefficient in hot and cold conditions, low wear rate, low noise, high corrosion resistance, manufacturing and usage economy and environmental friendliness. The aim of this thesis is to produce an environmentally friendly recipe by updating the existing brake lining constituents with high amounts of waste fly ash and waste tire rubber particles. It is aimed to use all the materials to be used here with minimal pre-treatment and thus to obtain economy in manufacturing process. Determining the ratios of the constituents to be used in the composition is an important issue and once the manufacturers obtain a suitable recipe, they do not want to change it. For this reason, the use of waste by products is limited. In this thesis, the fuzzy logic approach will be used together with literature data to keep the experimental studies in the process of determining the constituent ratios economical and viable for low cost. Within the scope of the thesis, fly ash obtained from thermal power plants in our country and waste tire rubber obtained from local recycling centers will be utilised. Various recipes will be prepared based on current literature data and experiences. In these recipes, attention will be paid to the use of high amounts of waste materials and the results obtained will be scored according to various physical and characteristic properties and a fuzzy logic membership function list will be obtained. Then, suitable recipes will be selected according to this list and comprehensive laboratory evaluations will be made. As a result of the evaluation, preferred and commercially suitable recipes will be selected and tests will be continued. As a result, the recipes suitable for commercial use will be manufactured in a factory environment under real manufacturing conditions and the study will be completed by testing the brake linings in accordance with ISO, ASTM and SAE standards. Thus, by using existing literature data, trial-and-error studies with the fuzzy logic method will be reduced to a limited number, and it will be shown that the studies performed are economical, and it will be shown that commercial companies can quickly and economically carry out studies on adding waste by-products to their existing recipes. Composite brake linings are made up of metal and organic constituents consisting of various powders, fibers and particles. These constituents are mixed to form a homogeneous structure and pres-moulded into the desired shapes and kept in a controlled oven environment for a certain period of time to cure and manufacturing is carried out. In composite brake lining manufacturing, information such as the form, ratio and manufacturing parameters of the materials used in the brake lining composition are not shared by the companies due to being trade secrets. Although the effects of these constituents have been examined with studies conducted in the literature, the results are not suitable for commercial manufacturing. The reasons for this are that the mechanical and chemical properties of the constituents used in the composition cannot be guaranteed by the manufacturers, and the country and region-specific characteristics of fly ash and organic constituents are among the reasons. Therefore, determining a new brake lining composition and manufacturing method requires long studies supported by trial and error and examination of literature data. Since very few global companies have the budget and resources to conduct such studies, changing a determined recipe is not on the agenda unless there are legal or market obligations. As a result, the commercial use of waste constituents such as fly ash and waste tire rubber remains limited. It is a necessity for companies to conduct R&D studies for reasons such as performance improvement, economy, and commercial competition in existing composite brake linings. The performance criteria of a composite lining to be produced vary depending on the area of use. For this reason, companies produce very different composite linings with various constituent ratios. In addition, similar performance criteria vary from company to company. For all these reasons, companies stick to a certain manufacturing recipe and do not make any recipe changes unless compelling circumstances such as legal or commercial competition arise. Another reason for this is that the work to be done for composite linings is very expensive and laborious, and therefore far from being economical for many companies. For this reason, companies keep their existing recipes as trade secrets, and therefore literature studies remain limited. Increasing the use of inrubberrial waste, economical use of existing literature data for determining composite lining constituents and using the fuzzy logic method as a desired tool to make the desired R&D activities of existing commercial companies feasible have been discussed. Thus, the study that will be conducted within the scope of this thesis will conclude that companies can make faster and more economical prescription studies by supporting their existing experiences with literature data. It is important to bring the research to a fast and economical position by considering the existing commercial and literature results with the fuzzy logic approach and to shorten the necessary trial-and-error process. Within the scope of this thesis, commercial and literature studied composite linings were examined within the framework of the determined parameters. Sample lining constituents were obtained for various composites using fuzzy logic parameters prepared based on the examination results. These composites were manufactured in a laboratory environment and various tests were performed and constituent ratios were updated based on the test results. According to the results obtained in the last case, sample lining recipes suitable for commercial use were obtained. In this study, the effects of fly ash and waste tire rubber constituents on many physical and tribological properties such as wear rate, friction coefficient, internal shear strength, liquid absorption rate, hardness, density of composite brake linings were investigated using the fuzzy logic method and it was aimed to obtain a commercial lining composition containing a high amount of waste constituents. A fuzzy logic model was established for the initial prescriptions of the lining composition, which was created from the existing literature examples and the test results of various commercial lining samples. Various preliminary constituents were produced and tested in a laboratory environment and the fuzzy model was optimized according to the test results. Sample prescriptions taken from this optimized model were examined in the light of relevant experiences and 8 sample prescriptions were selected. Laboratory and real-scale samples were produced by taking these 8 sample prescriptions and comprehensive tests were performed. Within the scope of this thesis, with the aim of economic evaluation and environmental protection, the use of our country's thermal power plant fly ash and waste vehicle tire rubber has been emphasized. High rates of waste tire rubber and fly ash were used and by preferring brass instead of copper, environmentally friendly, economical and commercially suitable brake lining constituents were obtained. As a result of the study, 4 types of brake lining recipes suitable for commercial use were obtained using these wastes.
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