2011-05-(034)

Hub & Drum design and process review and validation

Rodrigo Cunha
rcunha10@ford.com

Silvia Faria Iombriller

siombril@ford.com

Thiago Vaz da Costa

tcosta10@ford.com

Ford Motor Company.

Copyright 2011 Society of Automotive Engineers, Inc

SUMMARY
The market demands increasingly low cost with
high quality vehicles. On each automotive system is
necessary perform design review and process review for
improvement, cost reduction and supplier nationalization
maintaining quality, eliminating waste and seeking
optimized ways
to achieve results using tools and
technologies available today.
This project focus was Hub and Drum system in
commercial vehicles application considering suppliers
nationalization, material communization and new product
validation and control process.
The main tools used on this development were:
Material analysis: hardness, traction limit, Yield
Strength, impact resistance, micro structure, degree of
nodularity and chemical composition;
Standards analysis: global, local, and corporate;
Design analysis: finite element structural calculus,
package analysis and tolerance review;
Vehicle: Testing and performance durability;
Bench test: hub dynamometer and drum dynamometer;
Process analysis: mounting sequence, balancing, sonic
speed for x-ray and retainer invitation angle.
Among the main goals achieved during this project
there are a complete design review of hub and drum
assembly with material communization, standards revision

and development process optimization, validation and

production.
INTRODUCTION
In a great technological advancement scenario
where automotive industry is, it becomes crucial to review
old projects and apply the most innovative development
concepts, ensuring components with optimized design as
highlights Huang (2009), maintaining however a high
quality level. When these are security items such concepts
and assumptions are fundamental, considering the vehicular
application.
During this project it was possible a research
related to drum brake system applied to heavy commercial
vehicles development concepts, focusing on hub and drum
set. The targets of this research were the history of the
components already in production, considering the
standards and specifications applied to them, as well as
development and production technologies and tools
currently available. This comprehensive analysis allowed a
project review seeking the best compromise between
efficiency and durability applied to safety components.
The FMEA was one of the tools used during the
development of this project for the project and for the
process. The use of these tools allowed a failure mode
analysis and the verification and prevention methods,
considering the different boundary conditions and the

dissipate heat. Graphite net is necessary to potentiate this

dissipation. This heat dissipation characteristic need to be
connected to deformation resistance under high
temperatures, because if the drum deform (become oval)
the lining can lose part of the contact area with the drum
therefore the brake will lose efficiency. Graphite is a hard
material, it suit perfectly to this application.
Totaling all this conditions, the chosen material for
the drum is Gray Casting Iron that has all the necessary
characteristics for this application. Figure 1 shows Gray
Casting Iron microstructure.

improvement alternatives to the design and production

process and control.
Initially it will be present the materials selection
methodology, followed by analysis of design and
manufacturing processes, concluding with validations in
both methods, bench and vehicular.
MATERIAL SELECTION
Due to a brake system component safety
characteristic, one of the most important steps of the Project
is the material selection. A wrong choice or analysis may
result in a serious failure and risk to the user. Thus, it is
utmost important take in consideration what are the
mechanical stresses that undergoes on every brake
component, the interfaces between the other brake
components, the unintended situation that the components
may suffer, and especially what is the use of the vehicle.
With all this information available it is necessary to check
which material fits perfectly in this use, it requires a
mechanical properties, chemical and microstructures
analysis of the materials that could be used, as indicated by
Beraldo & Luciano (2007).
On this project the hub and drum material where
analyzed separately.

Figure 1 - Gray Casting Iron microstructure

Drum

On Figure 1 shows the graphite (black), forming a

mesh which ensures the main characteristic of heat
resistance.
According to Chiaverini (1990), actually the most
widely alloy used for the manufacture of brake drums is
gray cast iron due to its characteristics of easy fusion and
casting, good mechanical strength, excellent machinability,
good wear resistance, good cushioning capacity and good
heat dissipation.

The drum forms a pair of friction with the lining.

When the driver activates the brake through the pedal the
lining which is a component that does not rotate with the
wheel touches the drum which is attached to the wheel,
until it slow down the speed or stops the vehicle. Due to
this action, in heavy trucks it means high stress and thermal
loads so the drum material needs a consistent material
characteristic definition as well as:

Hub

Yield strength;
Hardness;
Heat dissipation capacity;
Thermal fatigue resistance;
High temperature deformation resistance;
Corrosion resistance;

The hub is a structural component that support and

attach the wheel and drum brake assembly to the axle of the
vehicle. To perform its structural function, the main
necessary characteristics are:

Some of them are very peculiar to this application,

and among them the thermal characteristic stand out. When
the lining presses the drum it generates thermal increase
and consequently a heat concentration that can generate
thermal fatigue and/or thermal cracks. Due to these
characteristics the chosen material must have resistance to
thermal fatigue and high heat dissipation. One material that
gathers these characteristics is graphite, because it is a good
heat transmitter avoiding the heat concentration and fatigue.
Besides that graphite must be in a specific disposition to

Hardness
Impact resistance;
Fatigue resistance;
Machinability;
Corrosion resistance;

One of the major challenges of the choice of the

material for this application is combine impact resistance
and hardness, because this part will be subjected to the axle
loads and high impacts during the vehicle running.

Furthermore a high hardness is needed to avoid

deformations. However if this hardness is too high it could
make the material fragile and loose the impact resistance. A
material that can guarantee the hardness is graphite
however to ensure that the component does not become
fragile the graphite must have nodule form on its
microstructure. This way tensions will not concentrate and
it will not become brittle, being able to absorb impacts. Due
to these characteristics, the more suitable material for this
application is the ductile casting iron. Figure 2 shows the
microstructure of this material.

Drum
For the brake drum, the defined standard was a
corporate standard based on SAE J431 emphasizing the
details of the notch remove local.
Hub
For the wheel hub the defined standard was SAE
J434 applied to ductile casting iron.
Material tests
The material tests are a fundamental stage because
is the validation of the component supplier material and the
process, verifying if the material compose need to be
changed or if the suppliers process is controlled or need
some adjust to meet all the material and component
requirement. In addition is verified if the required
production demand will be attend.
The necessary tests for this use were classified as gray
casting iron (drum) and ductile casting iron (hub). Tests in
10 parts of each material where performed.
Gray Casting iron (Drum)

Figure 2 - Microstructure of the Ductile Casting Iron

For this type of material the below tests were
performed:

On figure 2 is possible to observe that the material

has nodular graphite (black) that guarantees the mechanical
properties.

Hardness;
Microstructure;
Yield strength;

Standards and material specifications

With the purpose of ensuring the material quality and
their specific characteristics, define the standards and
material specifications for the project becomes essential.
For the casting iron there are different public standards,
nationally (ABNT), those that are considered global (DIN,
ASTM, SAE) and the corporate rules that are usually
discussed only between the project participants.
The choice of the standard that will validate the
material is other important step of this project, because is
necessary apply it to different vehicle models, respecting
each model peculiarity as GVW, load distribution and
application. This standard communization reduces the
development and process cost reducing the final component
cost.
The main characteristics considered to define standards
and specifications were:

The results for each test are represented below:

1. Hardness
Figure 3 shows the results and the variation of the
tested parts hardness (measured in HB). It is observed that
the hardness is under control.
Xbar Chart of Dureza Cinzento
230

UCL=229.49

220

Sample Mean

210
200
_
_
X=186.85

190
180
170
160

150

Material characteristics
Strength that the part is subjected;
Standard availability and its revision
Material communization

LCL=144.21
140
1

5
6
Sample

10

Figure 3 Hardness Graphic Gray casting Iron

2. Microstructure

Xbar Chart of Dureza

200

UCL=198.44

Figure 4 shows the parts microstructure:

Sample Mean

190

180
_
_
X=169.95

170

160

Figure 4 Microstructure Photograph

150

It is verified that all microstructure present needle

form of graphite with about 90% of perlite and the rest of
ferrite, so the microstructure is under control.

LCL=141.46

140
1

5
6
Sample

10

Figure 6 - Hardness Graphic

3. Yield strength
2. Microstructure
Figure 5 shows the results and the variation of the
tested parts yield strength (measured in MPa). It is observed
that the Yield Strength is also under control.

Figure 7 shows the parts microstructure:

I Chart of LR cinzento
240
UCL=238.09

Individual Value

235

Figure 7 Microstructure Photograph

230

It is verified that all microstructure present nodule

form of graphite with about 90% of ferrite and the rest of
perlite, so the microstructure is under control.

_
X=224.5

225

220

215

3. Yield strength
LCL=210.91

210
1

5
6
Observation

Figure 8 shows the results and the variation of the

tested parts yield strength (measured in MPa). It is observed
that the Yield Strength is also under control.

10

Figure 5 - Yield Strength Graphic

I Chart of LR

Ductile Casting Iron (Hub)

650
UCL=622.3

For this material type the below tests were defined:

Individual Value

600

Hardness
Microstructure;
Yield strength;
Elongation;
Impact test;

550
_
X=527.6
500

450
LCL=432.9

The result for each test is represented below:

5
6
Observation

Figure 8 - Yield Strength Graphic

1. Hardness
Figure 6 shows the results and the variation of the
tested parts hardness (measured in HB). It is observed that
the hardness is under control.

10

4.

Figure 11 shows an example of generic Boundary

Diagram for this type of project.

Elongation

Figure 9 shows the results and the variation of the

tested parts elongation. It is observed that the Yield
Strength is also under control.
I Chart of Alongamento
20

UCL=19.71

Individual Value

18
16
_
X=13.8

14
12
10
8

Figure 11 Hub and Drum Assembly Boundary Diagram

LCL=7.89
1

5
6
Observation

10

The components project specifications were

defined respecting a corporate project guide (Hub and
Drum design guides) applying the peculiarities of
commercial vehicles.
Among the main project specifications reviewed
there are:

Figure 9 Elongation Graphic

5- Impact Test
Figure 10 shows the results and the variation of the
tested parts impact test (measured in Joule). It is under
control.

I Chart of Impacto
130
UCL=123.98

Individual Value

120

110
_
X=103

Useful life;
Functional dimensions
Concentricity;
Run out;
Balancing;
Perpendicularity;
Surface finish;
Paint.

100

Other important aspect reviewed on these

specifications is the peculiarity of the commercial vehicles
application for these components that in some cases allow a
bigger dimensional tolerance range without affect the
efficiency of the brake system components.
To conclude the dimensional study, besides the
tolerance analysis of each component separately, the
assembly study is fundamental as well as the other vehicle
components that have interface with it on the assembly
process or on the vehicle usage.
However, some specifications of the project are
directly linked to the material characteristics, and among
them we can mention:
Thermal Efficiency
Impact Resistance
The definition of these specifications has been
discussed during the selection of materials, however its
validation involve both bench tests and vehicle
performance.

90
LCL=82.02

80
1

5
6
Observation

10

Figure 10 Impact Test Graphic

PROJECT AND PROCESS ANALISYS
During the design analysis the first step was the
base project study and the project and process specification
analysis.
Through the DFMEA revision it was possible
observe which project specification would be fundamental
to guarantee the function and application both hub and
drum avoiding the failure modes.
To develop a consistent DFMEA is fundamental
considerate all boundary conditions which the hub and
drum assembly is subjected.

An important project analysis tool utilized to

verify those characteristics was finite elements study,
considering structural and thermal aspects. Both, Boniati &
Iturrioz, and Biswadip, S. (2006) showed the advantages
of using this virtual resource for defining and verifying the
brake drums.
Figure 12 shows one of the finite elements results
considering the applied pressure condition and the effect of
the thermal gradient on the component.

Other important improvement to guarantee the hub

structural integrity during the process was the sonic
velocity definition for X-ray verification.
Also on the component analysis and project
definitions, evaluations were conducted to the
specifications of surface finish and painting showing the
integrity of components at the end of the tests.
BENCH VALIDATION
To guarantee the proper project validation, after
the virtual analysis it was conducted a validation phase
through bench tests.
Inertial dynamometers were used for hub (figure
13) and drum (figure 14) validation.

Figure 12 Finite Elements analysis Drum

For some design characteristics definition, in
addition of the dimensional tolerances between the parts
studies were also considered the process conditions.
This process analysis was performed using the
critical and significant characteristics extracted from the
DFMEA, which were directed to PFMEA.
During this analysis, were considered those
characteristics to improve the production process,
respecting also the parts demand required and the
production history and its flaws.
There was a complete revision of process failure
modes analysis of the hub and the drum revising its process
sheets.
Some process characteristics were reviewed using
new machinery and tools available, which result in changes
on balancing sequence.
Other studied stage of the process was the analysis
of the possible components and assembly balancing process
considering the specific project characteristics.
Some design characteristics that directly affected
the assembly process where reviewed also such as assembly
tolerances and chamfers that could facilitate the assembly
process of the bearings and retainers.

Figure 13 Inertial Dynamometer hub

Figure 14 Inertial Dynamometer - drum

In order for validate the most critical design
features, the parts were subjected to tests although obtained
through the usual process it was attempted to reproduce the
project boundary conditions, thereby ensuring the
validation of the established tolerances.

The tests were performed considering the

corporate specifications merging with the supplier's
recommendation and considering the loads condition and
characteristics frequencies of the commercial vehicle
application.
It was simulated on dynamometers the drum brake
assembly suffering the brake action and possible impacts
validating on structural and thermal aspects.
Other important aspect considered during the tests
was the drum life analysis considering the lining
characteristics.

optimization of the development, validation and production

processes.
The use of virtual tools enabled a complete
dimensional and assembly tolerance study, updating the
process and the project.
The finite elements analysis was primordial to
validate the defined material characteristics as the
dimensional characteristics ensuring a high confidence of
the project on structural and thermal performance.
The quality tools such as Boundary Diagram,
DFMEA and PFMEA allowed a complete analysis of the
boundary condition and its implication on the process and
project.
The metallographic and material tests validated the
standards revision considered for the defined materials
Through the bench and finally the vehicular
certification, was possible validate the complete project,
process and application on the different vehicle application
considered.

VEHICLE VALIDATION
Besides the common brake homologation tests
such as CONTRAN 777/93, structural durability tests were
conducted for hub and also for drum.
The
specific
vehicle structural durability tests were performed according
to the corporate standards showing satisfactory
performance to meet the requirements of life and structural
integrity, applied to safety vehicle components.
On accelerated structural durability test performed
in order to validate the drum, besides the brake temperature,
were also monitored the lining and drum wear. In addition
the drum was frequently monitored related on thermal
cracks that could jeopardize its correct function.
On vehicle impact test for hub structural
validation, the test condition were also monitored and like
the structural dynamometer test, at the end a "cracks check"
was applied to ensure the better inspection of possible
failures as shown on figure 15.

REFERENCES
Beraldo, C. E. M; Luciano, M. A. Interference
verification of metallurgical characteristics in brake
efficiency of gray cast iron brake drums 2007
Biswadip, S. et al Numerical simulation of drum brake
cooling for heavy trucks SAE 2006-01-3214
Boniatti, D. L., Iturrioz, I. Anlise do comportamento de
fadiga para estruturas submetidas a temperaturas elevadas
aliadas a esforos cclicos.
Chiaverini, V. - Aos e Ferros Fundidos - Associao
Brasileira de Metalurgia e Materiais ABM, 1990.
CONTRAN 777/93
Drum Design Guide Ford 2006
Hub and Bearing Design Guide Ford 2007
Huang, Y. A low-cost material design of gray iron for
heavy-duty brake drums 2009

Figure 15 Hub with "cracks check"

Limpert, R. - Brake Design and Safety. Warrendale.

Society of Automotive Engineers, Inc., 1992.

CONCLUSIONS

SAE

During this project it was possible a full review of

the hub and drum assembly projects with materials
communization,
specific
standards
revision
and

J431

Automotive

gray

iron

castings

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