Carbon brush materials were manufactured following out a design of experiments, varying the mixing ratio of different carbon blacks, the size of particles to be molded, molding pressure and the graphitizing furnace. Measurements were made on lattice constant and crystallite sizes by means of X-ray diffraction and on physical properties of these materials, and then the rate of wear and the sound pressure level of sliding noise of brushes made of these materials were measured.
The factorial effect on these brush characteristics and correlation between these characteristics were investigated. From X-ray diffraction results, the crystallite size, Lc, was shown to be highly important for brush materials. As for the rate of brush wear, correlation with Young's modulus and Rockwell hardness (more than Scleroscope hardness) were significant, whereas for brush noise, the degree of graphitization of the brush material was considered significant except for the difference of raw materials.
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