Various kinds of friction materials were manufactured by adding 10%, 20%, and 30% of reduced iron, respectively, which has been obtained during the reduction process of blast furnace sludge extracted from the blast furnace, and its iron oxide, instead of existing barium sulfate(BaSO4) among the components of automobile brake friction materials. Fundamental physical property test and friction performance test, etc., using a brake dynamometer were carried out against these friction materials. Furthermore, when the expensive filling material, BaSO4 was substituted by reduced iron and added to the friction material, the added content of reduced iron for an excellent friction characteristic considering the heat emission temperature, wear, etc., was 10%. In the fundamental physical property test, as the added content of blast furnace sludge or reduced iron increased, and as the content increased, the shear strength and bonding strength of friction materials decreased, but both of them indicated sufficient strengths to be applied to a friction material. Even in the frictional performance test using a brake dynamometer, as the added content of blast furnace sludge or reduced iron increased, the friction coefficient reacted insensibly to brake deceleration, and its stability was improved.

The brake system drives the vehicle by converting the kinetic energy into thermal energy. The heat energy generated during the braking process increases the temperature of the structure. It causes thermal deformation due to overheating and causes cracks, noise, and vibration that degrade performance. However, it is not possible to fundamentally prevent the temperature rise of the brakes. There is a need for research on improving the heat dissipation performance by improving the shape of the brake. Therefore, this study analyzed the concentrated stress caused by overheating of the brake disc. In order to improve the performance of the disk, shape optimization design was performed. For stress and thermal analysis, the analysis was conducted using the finite element program ANSYS Transient Thermal and Structural tools. PIAnO (Process Integration and Design Optimization) was used to perform optimal design. In the formulation of the optimum design, the stress was minimized by satisfying the constraints. This study intends to present a new brake disc model by performing perforated shape and arrangement.

The objective of this study is to construct the inspection standards of motorcycle brake system performance. Based on the Korean Motor Vehicle Safety Standards (KMVSS), the Korean Motor Vehicle Inspection Standards (KMVI), the inspection standards of the International Motor Vehicle Inspection Committee (CITA), United Kingdom and Japan, three alternative brake performance criteria were suggested. The brake performance tests for 129 various models of used motorcycles were conducted for verifying the developed test equipment and suggested three alternative criteria. The total brake performance criterion is appropriately suggested to set at 50 %. Considering the KMVI or the CITA, the brake performance criterion of rear axle may suggested to set at 20 % or 25 %, either.

The purpose of this research is to reduce the weight of the brake system of vehicles and to increase braking performance and its durability and to shorten the stopping distance. The plans for light-weight vehicles are to develop light weight material itself which possesses superior properties and another way is to improve the manufacturing method of materials which have the better mechanical properties. And the materials used for this are aluminum alloy, magnesium alloy, titan alloy, steel, other metals, plastic, ceramic materials etc. In this research, aluminum is used for the main body of the break to reduce the weight of the brake and cast iron(SCM4), stainless steel(SUS304) and titan alloy(Ti Gr2) are used for the outer ring shape plate and assembled with bolts. Dynamometer test are braking performed on the brake disc. Based on the test results, stainless steel(SUS304) is optimized for the light-weight brake disc.

The Magneto-Rheological fluid is the suspended material having the ferromagnetic particles with micrometer size that can change properties by applying magnetic fields. In this paper, the shape design of the T-Flange Magneto-Rheological brake is conducted theoretically. The equations for transmitted torque are derived according to T-Flange configurations of the Magneto-Rheological brake. This feature has more output torque than conventional types. The validity of theoretical results is verified by conducting an analysis of an electromagnet using the finite element method. Then the effectiveness of braking torque is verified to reinforce by comparing the output torque of the conventional Magneto-Rheological brakes.