Metal Matrix Composite Explained

Making Metal Matrix Composite Functionally Gradient Metal Matrix Composite (MMC) by definition is a type of material with at least two constituent parts, one being a metal. The other may be a different metal or another material such as ceramic or organic compound. In our case, Aluminum alloy and ceramic particles are used.

The MMC ingot is cast using the highly patented process. This unique casting process allows for very tight control over the ceramic particle disbursement throughout the entire bandwidth of the friction ring.

In other words, the disc is functionally gradient. Fifty percent of the ceramic by volume is concentrated in the outermost portion of the friction ring, where it will see the highest temperature. Fifteen percent of the ceramic by volume is concentrated in the innermost portion of the friction ring where it will see lower temperature.

This effectively balances the internal stresses caused by the difference in temperature between the inner and outer portions of the friction ring.

Reduce Braking Time & Distance with Composite
A brake is a device for slowing or stopping the motion of a machine or vehicle. In the braking process, the kinetic energy lost by the moving part is usually translated to heat by friction. The rotor and brake pad must absorb this heat.

Note that kinetic energy increases with the square of the velocity (E=l/2 M V2). If the speed of a vehicle doubles, it has four times as much energy. The braking system must dissipate four times as much energy to stop the vehicle. Consequently, the braking distance is four times as long. Lightweight wheels and brakes (1 ½ lbs. for the 11 ½ Harley VS 6 lbs. for a stock stainless rotor greatly help.

Motorcycle Metal does not claim to be able to change the laws of physics, but through careful consideration of the application, available materials, and proven manufacturing processes, we claim that our products can mitigate, to some degree, the negative effects the laws of physics may have on a fast moving motorcycle.

3D Simulation of a Full-Contact Disc Brake System
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This example involves a Thermo-Mechanical Coupling (TMC) simulation of a full-contact disc brake system. The figure below shows the mesh used for both solid and thermal analysis. Friction between the disc and the stationary components leads to local heat generation, causing non-uniform thermal expansion, which consequently alters the contact and friction conditions. A fully coupled thermo-mechanical analysis is required to capture this behavior.

In the movie, we show the temperature variation during braking. The figure below shows the variation of contact pressure between the upper friction plate and the piston at different times. A significant change in contact pressure distribution occurs as the brake system heats up, leading to more severe contact conditions at the inner surface.