Papers by Keyword: Brake Pad

Abstract: This paper presents the comparative investigation of temperature distributions in the pin-on-disc tribo-contact with dry friction conditions. Heat generation and distribution mechanism in contact of a pin made by phenolic resin–based brake friction composite and 35HNL steel disc counter-face material were studied. Both experimental and simulation methods were used to study the temperature changes. In order to analyse the thermal effects, the change in the coefficient of friction with time were also characterized. Experimental friction tests performed on universal “pin-on-disc"-type friction and wear test machine model MMW-1. Interface temperature measurements of the disc was conducted non-contact type infra-red laser thermometer. Heat simulations were modelled via finite element method using COMSOL Multiphysics 5.5, Heat Transfer in Solid Module. The simulations helped to determine in the increase of temperature over selected time period. Obtained experimental results compared with results of numerical analysis.

Abstract: Hot molding is one of the most important processes for the manufacture of friction materials in automotive brake systems. That is because it has direct impacts on the physical and mechanical properties. Porosity and compressibility affect properties like brake vibration. This then affects brake noise. Therefore, the objective of this work was to study the effects of hot molding conditions on the porosity and compressibility of friction materials. The crucial parameters; molding pressure, temperature and holding time were varied in the hot molding process. Porosity and compressibility were investigated and analyzed in relation to the manufacturing parameters using statistical analysis. The results and the correlation coefficients (R²) show that molding pressure and holding time are the most significant effects on porosity and compressibility. They indicate that the hot molding parameters can adequately explain porosity and compressibility.

Abstract: This research is focused on the effect recycling dust (RD) on properties and performance of brake pad composites. Recycling dust was produced from grinding process of in-finishing products to standard thickness and was used as a new friction material in brake pads. Based on a simple experimental formulation, the proper type of recycling dust reused in brake pad formula was investigated by changing recycling dust type in mixing process. In the experiment, the properties of brake pads, hardness, density, porosity, and Young’s modulus were measured. Furthermore, the morphology and composition of recycling dust will be characterized by X-Ray Fluorescence (XRF), and Scanning Electron Microscopy (SEM). The developed composite brake pad showed that the value of density and compressibility increased while the value of hardness and Young’s modulus decreased by adding 10wt% of recycling dust to commercial brake pad formulation. Hence, the benefit of this work is using recycling dust as one of alternative fillers in disc brake pad materials without compromising the quality and performance.

Abstract: This study aims to reduce brake pad thickness and density variations by pressure equalization in the preforming process. Brake pads consist of fillers, lubricants, abrasives, reinforcing fibers, and binders. These are compacted together as raw materials. Each component is responsible for a different specific property to help the brake pad reduce the speed of the vehicle. The forming of a brake pad begins with compression of friction powder in a rigid mold with a complicated contour. It is then compacted by vertically pressing punches to form a body of complicated shape and homogeneous density. The strength of the brake pad, which is a main property in the compacted material, primarily depends on the type of fiber reinforcing material. Since the ability of fiber to flow is poor due to its high internal friction and its random arrangement. These two characteristics cause non uniformity in density and elastic modulus. Pressure equalization is an adjustment of the filling depth of the powder which otherwise would have an uneven fill inf the cavity of the mold. The pressure equalization of the filled powder is shown to correlate with the brake pad dimensional accuracy and uniformity of density.

Abstract: Brake pad is the combination of lining and metallic components, e.g. steel backing plate (disc brake) and aluminum brake shoe (drum brake). Shear bond strength plays a major role to provide the safety and/or drive performances. This work aimed to study the processing factors affected the bonding strength. The molding temperature couple with post-curing temperature was simultaneously analyzed in order to optimize the processing temperature. The shear bond strengths of metallic plates were continually investigated with regard to the effect of different surface treatments. The obtained results indicated that the mechanical strength was increased as the molding temperature raised in ranges of 160°C to 180°C. Conversely, the deterioration of adhesive strength was progressively presented with rising post curing temperature. In comparing different backing plate, aluminum showed the higher shear bond strength than that of steel plate. In fact, the weakened property of aluminum in nature would be easily destroyed by mechanical treatments. From the shear tested results, an increase of surface roughness was inversely changed the shear bond strength. On the other hand, the contact angle of water droplet affected directly to adhesive strength. It was suggested that an adding surface roughness, commonly used in automotive industry, was inappropriate criteria, whist geometrical surface should be taken into account for improving the shear bond strength. Moreover, the contact angle and mechanical interlocking were recommended to use as a criteria of brake pad shear strength.

Abstract: Controlled friction and wear are the prime requirements of a braking system. The generation of wear debris depends on the brake materials properties, which in turn controls the tribological behavior. Present study deals with the performance evaluation and failure analysis of two commercial brake pads. Tribo Testing Rig (TTR) was used to evaluate the performance of brake. The tests were performed by making a tribo-pair of brake pad against the rotating disc with varying speed and pressure conditions. The wear response was quantified by mass loss, while the friction was measured in terms of coefficient of friction. Virgin and worn surfaces were analyzed using X-ray diffractometer (XRD), energy dispersive spectroscopy (EDAX) and Scanning electron microscope (SEM) to understand the wear and friction mechanisms. It was found that the type of constituents present in the brake-pad material and their spatial distribution plays an important role in controlling the wear and friction behavior. The high wear and friction was attributed to the presence of bulky particles of Fe and Si.

Abstract: The sense of stability during vehicle braking is largely related to brake performance. Among the brake parts, the brake pad must be working properly to ensure the braking performance and stability of the vehicle. That is, brake pads are required to maintain a uniform pressure distribution during braking. In addition, brake pads must maintain a proper braking force during rapid increases in temperature. In this study, the three-dimensional finite element (FE) model was developed to determine the distribution of the contact pressure of the brake pad. The temperature distribution on the pad surface was confirmed. The sensitivity to changes in material properties was verified using the developed model. Pad wear due to friction can be predicted by confirming the thickness variation due to heat. A fully coupled thermo-mechanical analysis of the developed FE model was performed using ABAQUS.

Abstract: Composite development is very intense to replace heavy and expensive metallic materials. One application of composite is a brake pad for vehicle. The composite for brake lining is consisted of various components which are divided into reinforcement, binder, friction modifier and filler. Composite in this study is made with variation in weight of graphite, NBR, fly-ash and phenolic resin. The hardness test was carried out to investigate the mechanical properties of the composite. Observation of the composite surface was carried out using SEM. The hardness test shows that an appropriate composition of the phenolic, fly-ash and NBR was result in high hardness value of fly-ash/phenolic composite.

Abstract: The aim of this paper is to develop new natural fibre reinforced for automotive brake pad application. For this purpose, new brake pad sampleswere produced using Miscanthus as reinforcement ingredient. The other ingredients are Cashew, Alumina, Phenolic Resin, and Calcite. Three different laboratory formulations were prepared with varying Miscanthus fibre contents from 10, 25, and 40 (wt) and these formulations were moulded four different moulding pressure values such as 50, 100, 200, and 300 MPa. Sieve analysis, density, apparent density, and hardness properties of brake pad samples produced are examined.

Abstract: Two kinds of friction materials in small electric car were studied by optical microscope(OM), X-ray diffraction(XRD) and scanning electron microscope(SEM). A sample was composed by Fe-based materials, SiO2, Al2O3 as hard phases, graphite and CaS as lubrications and carbonate and sulfate as fillers. MgO in B sample can increase its hardness, high temperature resistance and friction resistance. The lubrications of B sample consist of graphite and ZnS.