1. 1

2. Major Performance Properties of Ideal Friction
Material
µ in the range of 0.35-0.45 depending on the type
of vehicles
Low fade & high recovery of the µ
Least sensitivity of µ to load & speed, humidity,
water, oils, brake-fluids, temperature etc.
Moderately low wear
Good conformability and compatibility with the
rotor
Resistance to low frequency vibrations &
squealing noise
High thermal stability
Eco-friendliness etc. 2

3. Categories of FM
• Resin
• Fibers
• Space fillers
• Functional fillers
(to improve some special properties such as
friction, wear
resistance, TC, processibility etc)
3

4. Points to consider for the design of experiment
S.n Properties Remarks.
o
1 Specific Gravity Weight of Caliper increases and may
cause Judder during Braking
2 Hardness Low hardness may cause faster wear
rate of the pads.
3 Heat Swell Higher Heat swell value may affect
severe Braking at high speed.
4 Bonding Shear Higher bonding strength is better for
Strength high speed driving of the vehicle
5 Friction as per Higher friction level is good, for
SAE-J661 achieving minimum stopping
Equivalent to distance at higher speed of the
IS-2742 vehicle.
6 Wear Loss Lower the wear loss higher the life of
the pads. 4

5. Ingredients Properties
Fiber Steel wool Good wear resistant raw materials
s Poor wear resistant but used for enhancing
Copper chips friction
Graphite good wear resistant raw materials because
of their good wear resistant capability.
Zircosil
Filler Poor wear resistant but used for enhancing
Barytes
s friction
Nitrile a good toughened rubber for the organic
Butadiene binder and has a positive effect to improve
Rubber wear
Binde To bind the rest of the ingredients in the
Phenolic Resin formulation
r 5

6. DEVELOPMENT OF BRAKE PAD
( METHODOLOGY)
FORMULATION WEIGHT
MIXING BULK DENSITY
COMPACTNESS,
PRE-FORMING UNIFORM LEVELLING,
CORRECT WEIGHT
TEMPERATURE,
CURING PRESSURE, VENT CYCLE
TEMPERATURE & TIME
POST-CURING CYCLE
CONFORMANCE TO PDS
FINISHING
MEASURING FRICTION
TESTING AND WEAR

7. Preparation of Brake Pads
Parent Selected Resin
composition
Compression
molding
T = 160°C
P = 17 to 21
Mpa
Time = 6 min.
Plough Type Shear Mixer
Chopper Speed-2800 RPM
Feeder RPM – 140
Post curing Final
product
Temp
120-160°C
for 8 hrs 7

8. Cavity filled with powder
Preform pressure = 170 Kg/cm2
8

9. Job after Preforming
9

10. Pressure = 17 Mpa

11. Post Curing
Cycle 1 - 200° C - 205°C – 2 hrs
Cycle 2 – 240°C – 245°C – 3.5 hrs.
11

12. Properties tested as per IS 2742 standards
S.N Final O.E brake
Properties Unit
o formulation pad
1 Specific Gravity - 2.54 2.60
2 Hardness HR S 95 90
3 Acetone Extract % 2.05 2.16
4 Heat Swell In mm 0.14 0.12
5 Loss on Ignition at 800o C % 24.86 20.45
Kg/Sq.c
6 Cold Shear 42 45
m
Hot Shear Test @ 200 C / 45 Kg/Sq.c
7 27 30
Minutes m
Co-efficient of Friction as Normal
8 0.460 0.495
per SAE J -661a Mue
Co-efficient of Friction as Hot
9 0.400 0.460
per SAE J -661a Mue
10 Wear % 4.2 2.5 12

13. Effect of Fiber Orientation
10 degrees
off y axis

14. Modulus Based on Fiber Angle