Detailed Project Report on brake pad and shoe
Detailed Project Report on brake pad and shoe
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BRAKE PAD AND SHOE
[CODE NO.3989]
Brake pads are known to be found in disc brake systems and are a flat piece of steel with a thick friction material on one side. The friction material of the disc brake systems varies as per the vehicle type and calliper type. The driver of the break pads is known to operate the disc brake by pushing his foot on the break pedal. This in turn pushes against the attached master cylinder.
The master cylinder is actually a kind of piston surrounded by the brake fluid. The fluid is known to move down the brake lines against the brake disc. This procedure is known to slow down the wheel at a significant level. It is to be noted well that the energy is released much from stopping the car’s motion which is converted into waste heat energy that needs to be dispersed.
It needs to be noted well that the disc has a relatively quick cooling time which offers a kind of stopping performance than drum brakes. Furthermore, it is obvious that the friction material layer becomes much thinner over time as a result of usage, and it becomes much essential for the brake pads to be replaced on urgent basis.
Brake lining exists across the brake shoe inside the brake drum systems. Brake shoes are a cured piece of metal wherein there is a kind of friction material foxed on one side. When brakes are applied by the driver, the attached wheel cylinder forces the brake shoe outward, which in turn is known to create friction between the drum and the lining. Now, the kinetic energy that is released is actually dissipated as heat energy.
It is important to know the difference between brake shoes and brake pads. In their breaking systems, brake shoes and pads are positioned quite differently The brake pads are known to be placed inside a calliper which is placed in the brake drum. Furthermore, it needs to be well understood that the break shoes last longer than the break pads and are well positioned for their normal function.
It is practically possible to have both brake pads and shoes on the same car which can be used as combination of the two fitted on the rear axle. The break pads and shoes are known to perform similar functions, but they are not the same thing. The break pads are actually a part of the disc break system, which sit inside the break drum. The break shoes are known to be forced outwards when the break pedal is pressed, which in turn pushes the inside of the break drum, slowing down the wheel.
It needs to be noted well that break pads are more heat resistant, making them perfect for the front axle of vehicles. Break pads do the best job of keeping water away from the disc and always keeping away the created friction. There are many variations of the break pads which accommodate different driving styles as well as different vehicles.
COST ESTIMATION
Plant Capacity 16000 Nos/Day
Land & Building (5000 sq.mt.) Rs 4.16 Cr
Plant & Machinery Rs 1.64 Cr.
Working Capital for 1 Month Rs 73.00 Lacs
Total Capital Investment Rs 6.94 Cr
Rate of Return 28%
Break Even Point 57%
INTRODUCTION
FIG DISC BRAKE ROTOR
FIG DISC BRAKE ASSEMBLIES
PROJECT LOACTION-HOSUR
CLIMATE
TRANSPORTATION
ROAD
RAIL
HOSUR RAILWAY STATION
AIR
MAIN REQUIREMENTS OF BRAKE
THE ACTUAL STOPPING DISTANCE OF VEHICLE WHILE BRAKING DEPENDS
ON THE FOLLOWING FACTORS:-
LASSIFICATION OF BRAKE SYSTEM:
1. ON THE BASIS OF MODE OF ACTUATION:
2. ON THE BASIS OF MODE OF OPERATION
3. ON THE BASIS OF ACTION ON FRONT OR REAR WHEELS
4. ON THE BASIS OF METHOD OF APPLICATION OF BRAKING CONTACT
B) TYPES OF BRAKE SYSTEMS
PARKING BRAKES
EMERGENCY BRAKES
ANATOMY OF A PAD
RAW MATERIALS
BRAKE PADS/SHOE MADE OF:-
BINDER (MATRIX) MATERIALS
ABRASIVE MATERIALS
FRICTION PRODUCERS / MODIFIERS
FILLERS, REINFORCEMENTS, AND MISCELLANEOUS
BRAKE MATERIALS AND ADDITIVE FUNCTIONALITY
ONE CAN GROUP BRAKE MATERIALS AND ADDITIVES BASED ON THEIR EXPECTED
FUNCTIONS AS FOLLOWS:
ABRASIVES
FRICTION PRODUCERS / MODIFIERS
FILLERS, REINFORCEMENTS, AND MISCELLANEOUS
BINDER (MATRIX) MATERIALS
BRAKE FRICTION DESIGNATIONS AND TYPICAL COMPOSITIONS
SAE RECOMMENDED PRACTICE J866A LISTS THE FOLLOWING CODES
AND ASSOCIATED FRICTION COEFFICIENTS:
ACCORDING TO COMMERCIAL LITERATURE THERE ARE SIGNIFICANT
LIMITATIONS REGARDING THE USE OF SAE EDGE CODES:
FORMULATION TREND
BRAKES ARE NOW MANUFACTURED FROM A VARIETY OF DIFFERENTMATERIALS
THAT MAY BE:
ASBESTOS PADS
SEMI-METALLIC PADS
NON-ASBESTOS ORGANIC PADS
LOW STEEL PADS
CARBON PADS
FORMULATION
BRAKE PAD
BRAKE LINING
FACTOR EFFECT THE DEVELOPMENT OF FRICTION BY THE BRAKE SYSTEM
BRAKE FADE
BREAKS ARE DESIGNED TO FADE.
OTHERS FACTORS THAT AFFECT THE OPERATION OF BRAKE SYSTEM
WEIGHT TRANSFER
WATER ON BRAKE LININGS
CHARACTERISTICS
BRAKES ARE OFTEN DESCRIBED ACCORDING TO SEVERAL CHARACTERISTICS
INCLUDING:
DISCS
ON MOTORCYCLES
A DRILLED MOTORCYCLE BRAKE DISC
ON BICYCLES
A MOUNTAIN BIKE DISC BRAKE
RACING
CERAMIC COMPOSITES
CERAMIC DISCS ARE USED IN SOME HIGH-PERFORMANCE CARS & HEAVY VEHICLES
BRAKE COMPONENTS
THIS LIST INCLUDES:
MAIN COMPONENTS OF A DISC BRAKE
VARIOUS PARTS OF DISC BRAKE
BRAKE ROTOR OR BRAKE DISK
SIZE OF ROTOR/DISC:
WHY LARGER DISC PROVIDES BETTER BRAKING?
TYPE OF DISC BRAKES
CROSS DRILLED ROTOR
THE MAIN ADVANTAGES OF THIS TYPE OF ROTOR ARE:
THERE ARE FEW DISADVANTAGES AS WELL
CROSS SLOTTED ROTORS
ITS ADVANTAGES ARE AS UNDER:
DISADVANTAGES:
PETAL ROTOR/WAVE DISK
ADVANTAGES OF PETAL DISCS:
THERE IS ONLY ONE MAJOR DISADVANTAGE OF THIS KIND OF DISC THAT IT
WEARS OUT THE PADS AT A FASTER RATE
DAMAGES CAUSED TO THE ROTOR
DRUM BRAKES-DETAILS
COMPONENTS
BACKING PLATE
BRAKE DRUM
WHEEL CYLINDER
BRAKE SHOE
IN OPERATION
NORMAL BRAKING
AUTOMATIC SELF-ADJUSTMENT
EMERGENCY BRAKE
ADVANTAGES
TO LIST ADVANTAGES OF DRUM BRAKES:
DISADVANTAGES
DISC BRAKE- DETAILS
COMPONENTS
BRAKING DISC
CALLIPERS
PISTONS AND CYLINDERS
BRAKE PADS
BRAKE SQUEAL
BICYCLES
ULTRA SONIC PROCESS AND SHOT BLASTING
ULTRASONIC CLEANING
TUMBLE SHOT BLASTING
FOR BETTER SHEAR COVERAGE – CONVEYOR SHOT BLASTING IS ALSO PREFERABLE
MANUFACTURING PROCESS (BRAKE PAD)
HOT PRESSING MACHINE
OVEN CURING
SURFACE GRINDING
SCORCHING
POWDER COATING
GAS FLAME TREATMENT
SHIM BONDING & PRESSING
FINISHING ASSEMBLY OPERATION
CODE PRINTING MACHINE
BRAKE PAD PRINTING MACHINE IS EQUIPMENT TO PRINTING INFORMATION
ON BACK SIDE OF BRAKE PADS,LIKE LOGO,BRAND,AND PART NUMBERS AND SO ON.
DOCK AUDIT
VERIFICATION OF DIMENSION
VISUAL INSPECTION
PACKAGING
PRODUCT TEST REPORTS
MANUFACTURING PROCESS (BRAKE SHOE)
TESTING OF PHYSICAL PROPERTIES FOR FRICTION MATERIALS
MIX TESTING
MOISTURE TESTING
BACKPLATE ROUGHNESS TESTING
BACK PLATE GLUE THICKNESS
GOGAN HARDNESS TESTING
DENSITY & POROSITY
ACETONE EXTRACTION
SHEAR STRENGTH TESTING
POWDER COATING TESTING
SALT SPRAY TESTING
SHIM BONDING TESTING (T-PULL)
MARKET POSITION
CHINA AND INDIA TO HOLD SIGNIFICANT SHARE OF GLOBAL TWO-WHEELER
BRAKE PADS MARKET
KEY PLAYERS OPERATING IN GLOBAL MARKET:2
MARKET, BY VEHICLE
MARKET, BY MATERIAL
MARKET, BY SALES CHANNEL
MARKET, BY POSITION
BRAKE SHOE MARKET: MARKET PARTICIPANTS
CUSTOMERS AND COMPETITORS
CUSTOMERS
MAJOR CUSTOMERS
A LIST OF 2W DISC BRAKE PAD
PROCESS FLOW DIAGRAM-BRAKE PAD
PROCESS FLOW DIAGRAM-BRAKE LINING
RAW MATERIAL
STAMPING
WELDING
HOT PRESSING
BONDING
GRINDING
RIVETING
DOCK AUDIT
PACKING
RAW MATERIAL PHOTOGRAPHS
BINDER
ABRASIVES
FRICTION PRODUCERS / MODIFIERS
FILLERS, REINFORCEMENTS, AND MISCELLANEOUS
MACHINERY PHOTOGRAPHS
BRAKE PAD
ULTRASONIC CLEANING
MULTI-FUNCTION MIXER
AUTOMATIC MATERIAL MIXING SYSTEM
BRAKE PAD FRICTION MATERIAL MIX MACHINE
GLUING MACHINE
POWDER COATING MACHINE
DUST COLLECTING SYSTEM
HOT OVEN MACHINE
SCORCHING MACHINE
RIVETING MACHINE
SLOT AND CHAMFER MACHINE
GRINDING MACHINE
COMBINED GRINDING MACHINE
6 WORKTABLES HOT PRESS
AIR COMPRESS MACHINE
BRAKE SHOE MANUFACTURING
STAMPING
WELDING
HOT PRESSING
BONDING
GRINDING
RIVETING
PACKING
PRODUCT PHOTOGRAPHS
APPENDIX – A:
1. COST OF PLANT ECONOMICS
2. LAND & BUILDING
3. PLANT AND MACHINERY
4. FIXED CAPITAL INVESTMENT
5. RAW MATERIAL
6. SALARY AND WAGES
7. UTILITIES AND OVERHEADS
8. TOTAL WORKING CAPITAL
9. COST OF PRODUCTION
10. PROFITABILITY ANALYSIS
11. BREAK EVEN POINT
12. RESOURCES OF FINANCE
13. INTEREST CHART
14. DEPRECIATION CHART
15. CASH FLOW STATEMENT
16. PROJECTED BALANCE SHEET
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