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Ug case studies

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  • you are from which college and what is the professor name
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  • and this fabrication methodology how u got it. may i know which plant u have utilized to do this project. you are from which college and name the professor who gave you.
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  • @sethuram2 where u have this setup i need to know for my work
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  • @SethuRam2 which college and may i know who is ur professor
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Ug case studies

  1. 1. 1
  2. 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. 3. Categories of FM• Resin• Fibers• Space fillers• Functional fillers(to improve some special properties such as friction, wearresistance, TC, processibility etc) 3
  4. 4. Points to consider for the design of experimentS.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. 5. Ingredients PropertiesFiber Steel wool Good wear resistant raw materialss Poor wear resistant but used for enhancing Copper chips friction Graphite good wear resistant raw materials because of their good wear resistant capability. ZircosilFiller Poor wear resistant but used for enhancing Barytess friction Nitrile a good toughened rubber for the organic Butadiene binder and has a positive effect to improve Rubber wearBinde To bind the rest of the ingredients in the Phenolic Resin formulationr 5
  6. 6. DEVELOPMENT OF BRAKE PAD ( METHODOLOGY) FORMULATION WEIGHT MIXING BULK DENSITY COMPACTNESS,PRE-FORMING UNIFORM LEVELLING, CORRECT WEIGHT TEMPERATURE, CURING PRESSURE, VENT CYCLE TEMPERATURE & TIMEPOST-CURING CYCLE CONFORMANCE TO PDS FINISHING MEASURING FRICTION TESTING AND WEAR
  7. 7. Preparation of Brake Pads Parent Selected Resincomposition 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. 8. Cavity filled with powder Preform pressure = 170 Kg/cm2 8
  9. 9. Job after Preforming 9
  10. 10. Pressure = 17 Mpa
  11. 11. Post Curing Cycle 1 - 200° C - 205°C – 2 hrsCycle 2 – 240°C – 245°C – 3.5 hrs. 11
  12. 12. Properties tested as per IS 2742 standardsS.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 Mue10 Wear % 4.2 2.5 12
  13. 13. Effect of Fiber Orientation 10 degrees off y axis
  14. 14. Modulus Based on Fiber Angle

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