Development and Experimental Validation of a Full-Scale Brake Disc/Pad Test Rig for Passenger Vehicles

Öz

Brake systems are among the most critical safety components in passenger vehicles, making the accurate evaluation of braking performance essential during the design and development process. This study presents the development of a low-cost, multifunctional brake test rig capable of evaluating the performance of disc–pad friction pairs under controlled laboratory conditions. The test rig consists of a hydraulic braking unit, an electric motor drive system, a frequency inverter, a hydraulic control unit, and a data acquisition system. Braking tests were performed using an OEM ventilated brake disc and pad set at an equivalent vehicle speed of 100 km/h under a hydraulic braking pressure of 20 bar. Vehicle speed, friction coefficient, and brake disc temperature were continuously monitored throughout the experiments. The results showed that the developed test rig provided stable and repeatable braking cycles. The coefficient of friction varied between 0.03 and 0.36, while the brake disc temperature gradually increased from approximately 60 °C to 80 °C during repeated braking cycles. The developed system successfully reproduced braking characteristics under the specified laboratory conditions and provides a practical, reliable, and cost-effective platform for brake performance evaluation and future friction material investigations.

Anahtar Kelimeler

• Brake test rig
• Disc/pad
• Braking performance
• Friction coefficient
• Dynamometer

Etik Beyan

Ethics committee approval was not required for this study because of there was no study on animals or humans.

Teşekkür

We would like to thank Karamanoğlu Mehmetbey University and the Department of Motor Vehicles and Transportation at the School of Technical Sciences for their support in the completion of this study.

Kaynakça

1. Agudelo, C. E., & Ferro, E. (2005). Technical overview of brake performance testing for original equipment and aftermarket industries in the US and European markets. Link Engineering.
2. Aksoy, S., Kabakcı, F., Acarer, M., Düzcükoğlu, H., Ünüvar, E., & Fındık, F. (2023). Effect of Mg addition on microstructure and mechanical properties of AlSi12 alloy produced by high-pressure casting method. Industrial Lubrication and Tribology, 75(1), 27–35. https://doi.org/10.1108/ILT-10-2021-0410
3. Aleksendrić, D. (2010). Neural network prediction of brake friction materials wear. Wear, 268(1–2), 117–125. https://doi.org/10.1016/j.wear.2009.07.006
4. Anderson, A., Gratch, S., & Hayes, H. P. (1967). A new laboratory friction and wear test for the characterization of brake linings (SAE Technical Paper No. 670079). SAE International. https://doi.org/10.4271/670079
5. Blau, P. J. (2001). Compositions, functions, and testing of friction brake materials and their additives (Report No. ORNL/TM-2001/64). Oak Ridge National Laboratory. https://doi.org/10.2172/788356
6. Blau, P. J. (2008). Friction science and technology: From concepts to applications (2nd ed.). CRC Press.
7. Burkman, A. J., & Hishley, F. H. (1967). Laboratory evaluation of brake lining materials (SAE Technical Paper No. 670510). SAE International. https://doi.org/10.4271/670510
8. Demir, A., Samur, R., & Kilicaslan, I. (2009). Investigation of the coatings applied onto brake discs on disc-brake pad pair. Metalurgija, 48(3), 161–166.

9. Eriksson, M., Bergman, F., & Jacobson, S. (2002). On the nature of tribological contact in automotive brakes. Wear, 252(1–2), 26–36. https://doi.org/10.1016/S0043-1648(01)00849-3
10. Filip, P., Kovarik, L., & Wright, M. A. (1997). Automotive brake lining characterization (SAE Technical Paper No. 973024). SAE International. https://doi.org/10.4271/973024
11. Filip, P., Weiss, Z., & Rafaja, D. (2002). On friction layer formation in polymer matrix composite materials for brake applications. Wear, 252(3–4), 189–198. https://doi.org/10.1016/S0043-1648(01)00873-0
12. Güneş, A., Düzcükoğlu, H., Salur, E., Aslan, A., & Şahin, Ö. S. (2023). Investigation of friction coefficient changes in recycled composite materials under constant load. Lubricants, 11(9), Article 407. https://doi.org/10.3390/lubricants11090407
13. Güney, B., Küçüksarıyıldız, H., & Mutlu, İ. (2025). Investigation of microstructural and tribological properties of a commercial brake pad. Science of Sintering, 57(4), 487–501. https://doi.org/10.2298/SOS241217010G
14. Güney, B., & Mutlu, İ. (2015). Taşıtlarda AB ve ABD’nde uygulanan fren test standartlarının incelenmesi [Investigation of brake test standards applied in the EU and the USA in vehicles]. Afyon Kocatepe Üniversitesi Fen ve Mühendislik Bilimleri Dergisi, 15(1), 7–16. https://doi.org/10.5578/fmbd.8524
15. Güney, B., & Mutlu, İ. (2019). Tribological properties of brake discs coated with Cr2O3–40% TiO2 by plasma spraying. Surface Review and Letters, 26(10), Article 1950075. https://doi.org/10.1142/S0218625X19500756
16. Jaafar, T. R., Selamat, M. S., & Kasiran, R. (2012). Selection of best formulation for semi-metallic brake friction materials development. Powder Metallurgy, 55(1), 30–34.
17. Kancharla, S. C. R. (2014). Model brake material formulations and their testing at different scale levels [Doctoral dissertation, Southern Illinois University Carbondale]. OpenSIUC.
18. Kumar, M., & Bijwe, J. (2010). NAO friction materials with various metal powders: Tribological evaluation on full-scale inertia dynamometer. Wear, 269(11–12), 826–837. https://doi.org/10.1016/j.wear.2010.08.011
19. Lee, P. W. (2013). Design and optimization of low-Cu and Cu-free automotive brake friction materials [Doctoral dissertation, Southern Illinois University Carbondale]. OpenSIUC.
20. Lee, P. W., Leist, J., & Filip, P. (2010). Use of hexagonal boron nitride in automotive friction materials (SAE Technical Paper No. 2010-01-1700). SAE International. https://doi.org/10.4271/2010-01-1700
21. Malachova, K., Kukutschova, J., Rybkova, Z., Sezimova, H., Placha, D., Cabanova, K., & Filip, P. (2016). Toxicity and mutagenicity of low-metallic automotive brake pad materials. Ecotoxicology and Environmental Safety, 131, 37–44. https://doi.org/10.1016/j.ecoenv.2016.05.003
22. Perzborn, N., Agudelo, C., & Ostermeyer, G. P. (2014). On similarities and differences of measurements on inertia dynamometer and scale testing tribometer for friction coefficient evaluation. SAE International Journal of Materials and Manufacturing, 8(1), 104–117. https://doi.org/10.4271/2014-01-2523
23. Rita, D. A., Candeo, S., Jayashree, P., Nogueira, A. P. G., Rustighi, E., & Straffelini, G. (2024). Comparative analysis of pin-on-disc and inertia-dynamometer sliding tests on a friction material. Wear, 558–559, Article 205552. https://doi.org/10.1016/j.wear.2024.205552
24. Rudas Florez, J. S. (2018). Dry sliding metals process modelling: Dynamical system paradigm [Doctoral dissertation, University of Sheffield]. White Rose Research Online.
25. SAE. (1967). Brake lining quality test procedure (SAE J661_196702). SAE International.
26. SAE. (2014). Dynamometer global brake effectiveness (SAE J2707_201402). SAE International.
27. Sanders, P. G., Dalka, T., & Basch, R. (2001). A reduced-scale brake dynamometer for friction characterization. Tribology International, 34(9), 609–615. https://doi.org/10.1016/S0301-679X(01)00053-6
28. Singireddy, V. R., Jogineedi, R., Kancharla, S. K., Farokhzadeh, K., & Filip, P. (2022). On scaled-down bench testing to accelerate the development of novel friction brake materials. Tribology International, 174, Article 107754. https://doi.org/10.1016/j.triboint.2022.107754
29. Spencer, A., Spurgeon, W. M., & Winge, J. (1966). Four tests for consistency of automotive brake linings (SAE Technical Paper No. 660412). SAE International. https://doi.org/10.4271/660412
30. Tsang, P., Jacko, M., & Rhee, S. (1985). Comparison of chase and inertial brake dynamometer testing of automotive friction materials. Wear, 103(3), 217–232. https://doi.org/10.1016/0043-1648(85)90012-2
31. TSE. (1992). Karayolu taşıtları - Fren sistemleri balatalar - Sürtünmeli frenler için [Road vehicles - Brake systems linings - For friction brakes] (TS 555). Turkish Standards Institution.
32. Tuszyński, W., Gibała, M., Gospodarczyk, A., Kozioł, S., Matecki, K., Piekoszewski, W., Siczek, M., Szczerek, M., & Wojutyński, J. (2019). The new inertia dynamometer for friction and wear testing of brake pads and brake discs. Tribologia, 286(4), 113–119. https://doi.org/10.5604/01.3001.0013.6300
33. Varriale, F., Candeo, S., Riva, G., Wahlström, J., & Lyu, Y. (2022). A brake system coefficient of friction estimation using 3D friction maps. Lubricants, 10(7), Article 134. https://doi.org/10.3390/lubricants10070134
34. Wang, Q., Zhang, X., Wang, D., Cui, H., Zhang, S., & Wang, J. (2025). Numerical simulation and experimental investigation on the thermal-fluid-solid multi-physical field coupling characteristics of wet friction pairs considering cavitation effect. Applied Thermal Engineering, 260, Article 124955. https://doi.org/10.1016/j.applthermaleng.2024.124955
35. Yun, R., Filip, P., & Lu, Y. (2010). Performance and evaluation of eco-friendly brake friction materials. Tribology International, 43(11), 2010–2019. https://doi.org/10.1016/j.triboint.2010.05.001