proprietary information of akebono © 2005. all rights reserved. akebono overview and reduced copper...
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Proprietary Information of Akebono © 2005.All rights reserved.
Akebono Overview and Reduced Copper Friction
Material DevelopmentJune 22, 2005
Proprietary Information of Akebono © 2005.All rights reserved.
Company OutlineCompany Outline
Established: January, 1929
Capital: $ 90 Million
Annual Sales （ FY2004 consolidated ）： $1.34 Billion
Employment （ Mar. 2003, Consolidated ）： 4,554 Staff
（ Japan ： 3,500, Overseas:1,054 ） Licensees ： in 13 countries, 16 Companies （ USA,
France, Taiwan, Australia, Malaysia, Philippines, India,
Mexico, Columbia, Brazil, Spain, Indonesia, Portugal)
Proprietary Information of Akebono © 2005.All rights reserved.
HistoryHistory1929Established as Akebono Asbestos Industry; started
production of lining & clutch facing
1936Reorganized to Akebono Asbestos Industry Co., Ltd.
1940 Hanyu Plant started operation
1954 Started production of clutch facing materials at Hanyu Plant
1960 Started production of drum brake
1965 Started production of disc brake 1978 Started production of non-asbestos disc pad
1982 Awarded prize by Mechanical Engineering Society of Japan for AD Disc Brake self-developed by Akebono
1988 Ambrake (USA) started production
1996 Amak Brake (USA) started production
1999 Akebono Arras (France) started production
2001Amtec Brake (USA) started production
2003 Akebono Brake Asia Office was incorporated
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Foundation brakes Disc brakes
(1 pot, 2 pot, integral, DIH) Drum brakes
(servo, non-servo & 2 leading shoe)
Disc pads Drum linings
Brake apply system Motorcycle master cylinder Proportional valves Dual control valves
ABS Hydraulic
Modulators Sensors
Powertrain Retarders Clutch facings
Main ProductsMain Products
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Main ProductsMain Products
Disc Brake Assy
Pad for Disc Brake
Drum Brake Linings
Drum Brake Assy
ABS, ESP Sensor
Disc Brake Assy for Rolling Stock (Trains)
Disc Brake Pad for Rolling Stock
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Sales by ProductSales by Product
Others5%
Rolling stock3%
Sensor1%
Ind. Machinery4%
DrumBrake
14%Disc Pad
30%
OtherAuto-parts
16%
DiscBrake
27%
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North American OE CustomersNorth American OE Customers
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North American Interface North American Interface CustomersCustomers
Sumitomo
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Tri-polar NetworkTri-polar Network
Manufacturing/Sales/R&D Manufacturing/Sales/
R&D
EuropeEurope North North AmericaAmerica
AsiaAsia
Manufacturing/Sales/R&D
Including Japan
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Engineering CentersEngineering Centers
Function
Technical application to local customers
Local R&D activities
Technical support to local production
Facilities
Prototype manufacturing (friction material)
Dynamometer (prototype test)
Material evaluation (raw materials)
CAD (on-line communication with Akebono R&D)
Akebono Brake R&D Center Ltd. Akebono R&D Division
Hanyu/Japan
CREACentre de Research
Akebono EuropeGonesse/France
Akebono Corporation NA Engineering
Center Farmington Hills, MI
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Service Parts OperationRemanufacturing &
PackagingMunfordville, KY
AMAK Brake (JV)Glasgow, KY
HeadquartersSales, Marketing &
EngineeringFarmington Hills, MI
AMBRAKE (JV)Elizabethtown, KY
Akebono in North AmericaAkebono in North America
AMTECSpringfield, KY
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Friction Material Development HistoryFriction Material Development History
Asbestos Semi-Met.
Concerns– Life– Noise– Fade– HS&E
– High Thermal Conductivity– Rust– Creep Groan– Wheel Dust– Low Friction
Low Steel
NAO
High Speed
High LoadsHigh Temp. Friction Stability
Future
1970 75 200095908580 2005
- The New Generation
AKEBONO starts in USA
- Toxicology
Proprietary Information of Akebono © 2005.All rights reserved.
Binder
Resin
Organic
Fiber
Inorganic
Fiber
Metallic
Powder
Solid
Lubricant
Steel
Fiber
Other
Metal Fiber
Organic
Fillers
Inorganic
Fillers
Abrasives
Output - -
Fade - -
Squeal - -
Groan - - - - - - - - -
Rotor
Wear
- - - - - -
Low oC
Life
- - - -
High oC
Life
- -
Judder - - - - - - -
Ingredient Influences on Friction MaterialIngredient Influences on Friction Material
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Friction Stability (Mu vs. Deceleration)Friction Stability (Mu vs. Deceleration)
0.25
0.3
0.35
0.4
0.45
0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1
Akebono NAOSemi-mets
+ NAO’s give predictable, stable performance
Typical Stop“Panic Stop”
Performance
Gap
Mu
(outp
ut)
Deceleration (g)
Controlled Initial Brake Temperature
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Rotor Matrix : SofterFeO ― Mohs 3
Fe3O4 ― Mohs 7
Thin transfer film - Larger particles and abrasives are exposed
Rotor Texture
Hardened Layer ～ 300μmOxidation Layer
Gas AdsorptionLayer
Transfer Film ～ 20μm
Transfer Film
Deteriorated LayerFriction Mat’l Texture
Rotor
Wear Debris (including copper) & Oxidation Film
Pad
1st Body1st Body
2nd Body2nd Body
Third Body ConceptThird Body Concept
AdhesiveAdhesive
Good NVHMild WearGood NVHMild Wear
High Output High wearHigh Output High wear
TribologyTribologyTribologyTribology
Wear Debris of Rotor (Iron Oxide:Harder ）
Fe2O3 ― Mohs 5
AbrasiveAbrasive
Thicker Transfer Film - Larger particles, includingabrasives, remain covered
Graphite
3rd Body3rd Body
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Performance ComparisonPerformance Comparison
Performance Test - Result SummarySUV class vehicle
0.10
0.15
0.20
0.25
0.30
0.35
0.40
0.45
0.50
(Lin
ing
Eff
ec
tiv
en
es
s -
mu
)
NS-308H NS265H BP5445E2