ECONOMIC VIABILITY OF BASALT-BASED BRAKE PAD IN NIGERIA

The economic analysis reveals the basic information on the expenditure and profit to an investor who is willing to invest on the production of basalt-based brake pad in Nigeria, Nigeria has huge demand of brake as revealed by data obtained from National Bureau of Statistics Abuja (NBS). The analysis was based on deductive economic analysis which assumptions were made and arrived at particular result and the costing was based on Activity-Based Costing (ABC) where overhead and indirect cost were assigned to the related product. The economic analysis will give an insight to an investor (s) who has been skeptic about investing in the manufacturing of brake pad in Nigeria. The analysis revealed that the total capital require for this investment is #54,520,184.00 to set up a manufacturing plant with a capacity of 12,960 pieces of brake pad per day with a depreciation period of ten years. It also showed that if the line will run at 75% efficiency, the annual production is 2,566,080 pieces of brake pads. The unit cost of production is #520.85, unit selling price is #572.935, interest before tax of #6,797,983.869, break-even quantity of 861,019pieces, payback period of eight months. The annual total cost of production is #1,373,924,104.00, annual total sales revenue of #1,470,309,952.00.Twenty-seven people are require for manning the plant.It is clear from above information the investment is worthwhile because of the good payback period and considering the huge demand in Nigeria.

Synergistic effects of iron and hexagonal-Boron Nitride additions in copper-based composites for braking application

This paper explores the addition of h-BN and iron to Cu-based brake pads on the performance benefits. It also investigates the effect of graded layering by synthesizing three and four-layer brake pads by powder compaction and sintering route. The top one or two layers are made of Cu-based composite containing Fe, h-BN, and W, while the middle layer is pure Cu and, bottom steel plate. Two different compositions were explored for the composites by varying Fe content. From the two composite compositions, brake pads with single-layer composite or two-layer composite were synthesized. Characterization of brake pad specimens was carried out using density measurements, optical microscopy, scanning electron microscopy, energy dispersive spectroscopy. The brake pads were subjected to simulated braking tests at braking energy/cycle of 60, 96, and 136 K Joules. Wear rate, coefficient of friction, stopping distance, stopping time, and hardness were measured and compared among other brake pads. The brake pad containing single-layer Fe rich Cu composite showed the best performance in the simulated braking tests. EDS analysis of wear debris shows the formation of iron (boride, nitride, oxide) complex which is indicative of a surface with superior dry lubricating properties. This surface is a result of synergetic interaction between h-BN and Fe particles. The iron particles which are scattered in the Cu matrix composite act as low friction regions on the brake pad surface that interrupt the high friction regions on the Cu matrix, thus reducing the local and bulk temperature rise. The two-layer composite brake-pad showed performance intermediate to the two single-layer brake pads. No advantage due to higher thermal conductivities in Fe deficient composite was observed as the two composite layers, showed similar Fe contents in their matrix phases.

Experimental investigation on the friction characteristics of hazelnut powder reinforced brake pad

After the realization that asbestos fiber is harmful to human health, efforts to produce organic and environmentally friendly brake pads have increased. In this study, an environmentally friendly brake pad (NUS sample) was produced with the addition of 3.5% hazelnut shell powder. Hardness and density measurements of the brake pad sample were made. Chase type device was used for the wear and friction tests. The experiments were done according to the SAE J661 standard. The average friction coefficient value obtained as a result of the experiments was found to be 0.435 µ. Bu değer standartlara uygundur ve “FF” sınıfı aralığındadır. This value complies with the standards and is in the "FF" class range.

Effects of Particle Size and Composite Composition of Carbon Microparticles as Reinforcement Components on Resin-Based Brake Pad Performance

This study aims to investigate the effect of particle size and composition of bamboo and clove leaves as reinforcement components on resin-based brake pad performance. Bamboo fibers contain cellulose and lignin, making them better mechanical properties compared to glass fibers. Clove leaves due to their containment of oil components can be used, playing roles in binding bamboo with resin material. In short, experiments were done by involving polymerization of polyester resin as an adhesive with methyl ethyl ketone peroxide (MEKP) at room temperature. The composition of polyester/MEKP/reinforcing components was fixed at a mass ratio of 10/1/1.76 and the particle size of the reinforcing components were 582 and 250 m. Reinforcing components were mixed carbonized bamboo fiber and dried clove leaves with a ratio of 4/1; 7/1; and 10/1. The results showed that smaller particles has better mechanical properties, and the more amount of bamboo particles give positive impacts on the material hardness. The best hardness value (reaching 24 N/cm2) and smallest pore volume (0.0213 cm3) were obtained when using the ratio of 10:1. While the smallest weight loss of mass at the rate of 0.1225 g/min was obtained by the ratio of 7/1. The largest friction coefficient and lowest wear rate were obtained by 4/1 with a value of 0.1108 and 1.08 g/s.mm2, respectively. This study demonstrates the use of biomass waste such as bamboo fiber and dried clove leaves as an alternative to asbestos and reduces the abundant waste of bamboo powder and dried clove leaves in Indonesia.

Effects of Particle Size and Composite Composition of Durian Peels and Banana Midribs' as Reinforcement Components on Resin-Based Brake Pad Performance

This study aims to determine the effect of particle size and material composition on the performance of resin-based brake pads. Experiments were carried out by mixing 75% UPR with durian peel and banana midribs fibers using ratios of 1/1, 3/2, and 2/3 at particle sizes of 104 and 250 μm. The experimental results shows that decreasing the particle size improves the mechanical properties of brake pads, but gives a high wear value and a low coefficient of friction. In addition, an increase in the percentage of banana midrib fibers as a whole provides better brake pad performance. The results of the comparison between commercial-based brake pads confirm that agricultural waste is potential as an alternative to friction materials in brake pads. Brake pad with a fiber ratio of 2/3 104 μm had highest values of hardness, wear and friction coefficient, namely 20.33 N/cm3, 2.02 x 10-4 g/s.mm2, and 0.2465. while the 1/1 250 μm and 3/2 250 μm had the lowest coefficient values and compressive strength of 0.1195 and 9.14 N/cm3. This study demonstrates the use of biomass waste as an alternative to friction material to overcome the dangerous problem of using asbestos in brake pads.

Thermo-Structural Analysis of Brake Disc-Pad Assembly of an Automotive Braking System

Braking is a phenomenon of stabilizing a moving vehicle to rest by actuating the braking system. The available kinetic energy from the dynamic body is transformed into mechanical energy by the braking system which is further converted into thermal energy for its dissipation into the surroundings. During the process of braking, the frictional contact between the brake disc and brake pad creates enormous amount of heat elevating the temperature of the system to a higher level. The objective of this numerical study is to minimize the heat produced during the braking process. Three unique ventilated brake disc and two brake pad profiles were developed using PTC Creo modelling tool and were subjected to ANSYS workbench to evaluate its thermal and structural performance with a braking cycle time of 4.50 sec. Total deformation, equivalent stress, temperature distribution and total heal flux were assessed. Based on the study, ventilated disc 3 can be the possible design with either of the brake pad profiles for effective usage in the automotive braking system.

Introduction of innovative technologies in friction units of heavy-duty tribosystems and monitoring of their condition

The article describes studies of heavy-duty metal-polymer tribosystems: wheel-brake pad and pyatnik-podpyatnik of rolling stock, as well as spline couplings of the MI-26 helicopter tail rotor transmission. Tests of the wheel - brake pad system were carried out on an inertial stand with two-way braking at loads and speeds close to real operating conditions. Methods for modifying polymers, fillers, and nanoscale additives have been developed for the Pyatnik - podpyatnik tribosystem of rolling stock. To increase the wear resistance of work surfaces two-layer carbon fibers were applied to the spline couplings. DLC- coatings. Bench tests of these coatings showed a 4.5-fold reduction in wear when testing full-scale slots with a load of 30,000 kg. H and the number of completed cycles in 1,000,000. Methods for monitoring spline couplings based on the analysis of the frequency spectrum of the acoustic-emission (AE) vibration signal generated during the operation of the friction unit are considered. The results of studying the working state of spline couplings obtained by vibration diagnostics in the acoustic frequency range are presented. The state estimation is based on both the characteristics of the time signal and the transformation of the signal in the frequency domain using modal decomposition of the signal using Hilbert-Huang transformations. It is shown that for the effective for monitoring heavy-duty tribosystems, it is advisable to use neural networks.

New Developments in Carbon-Based Nanomaterials for Automotive Brake Pad Applications and Future Challenges

The proper functioning of automotive brake pads is of utmost importance to ensure the safety of passengers. Therefore, brake pad materials must be chosen with utmost precision and care to ensure their optimal functioning for long durations. Through a thorough literature review, it is found that the materials used currently for this purpose pose multiple discrepancies. Therefore, it is imperative to shift our focus towards nanomaterials, as they are one of the essential novel materials in this field. This study discusses the multiple constituents used in commercial brake pads, their role in improving and stabilizing their operation, and their desired properties to achieve optimal functioning. Parallelly, this study also reviews some of the potential organic and carbon nanomaterials that could prove to provide tough competition to currently utilized materials for brake pad applications. From this review, the major future commercial brake pad materials obtained include the likes of banana peel powder, crab shell powder, coconut fibers, stark corn fibers, metal oxide composites, metal nitride composites, multiwalled carbon nanotubes, and hybrid nanocomposites. These materials are studied on the basis of their performance under high-frictional force applications and analyzed by considering their mechanical, chemical, thermal, and tribological properties. Carbon nanotube-based composites showed improved tribological and braking performances making them more attractive than the materials in commercially available brake pads. In addition to these, the effects of usage of such nanomaterials on the environment and health are reviewed, in order to understand the feasibility of utilization of nanomaterials in automotive brake pad applications. From this analysis, this work suggests that there are a variety of nanomaterials that prove to be capable of automotive brake pad applications and, with further research and technological developments, would prove to be an asset to the automotive brake pad industry.