Product development in

Production

BRAKE PADS: Design and

Maintainability

Contents:

1:
2:
3:
4:

Introduction
Production Stages
Size Ranges
Maintainability

NACHIKET KULKARNI

Source: http://auto.howstufworks.com/auto-parts/brakes

Fig 1: Brake

INTRODUCTION
Brake Pads is a frictional device, That uses
pressure and friction.
Design to exert frictional force to stop the
disk or rotor.

Its has a caliper mechanism, Pistons press on

friction pads that clamp against the disc from
each side to slow or stop.

Application from Automobiles, locomotives,

Bicycles, and Jumbo jets.

BRAKE PAD

PRODUCTION STAGES
Product
Development

Dimensioning

Product

*Manufacture
Components

Quality Testing

Design Validation

*Assembly

Fig 2: Production Stages

CAD/CAE operations
* CAM Operations

SIZE RANGES

Fig 3: Analysis of
frictional force

http://www.eos.ubc.ca/courses/eosc256/Mar_11_2011_friction.pdf

BRAKING TORQUE
Nm = N x r
(Nm) = Braking Torque
(N) = Braking Force
(r) = Effective Disc Radius

=
http://www.twiflex.com/documents/PDF/Spring-Applied/MX-Series/DS2513%
20HR.pdf
http://imgkid.com/brake-repair.shtml

TEMPERATURE RISE

http://www.engineeringinspiration.co.uk/brakecalcs.html

TEMPERATURE RISE
1.2

0.8

0.6

0.4

0.2

0
1

1.2

1.4

1.6

1.8

2.2

2.4

2.6

2.8

FAILURE MODE AND EFFECTS ANALYSIS

1

1
7

ANALYSE
PRODUCT
DESIGN
2

ACTION &
FOLLOW UP

RISK PRIORITY
NUMBER

5
Fig 5: FMEA
cycle

DETECTION
RATING

FMEA
CYCL
E

DETECT FAILURE
MODES

PROBABILITY
RATING

SEVERITY
RATING

Source:Local AutoZone store.

FMEA redesign solution

Conditions that indicate when to change
brake pads

To prolong life of the braking

rotor, wear indicator should be
attached to the pad.

Friction
material

Pad should be changed when the

wear indicator has worn-out to
inch of its original length.

Brake pads can also be changed

when it takes a long time to stop.
Fig6: FMEA
improvement

Features for preventive

maintenance.
Uses of Standard components and
fasteners.
Pads should be easily removed with
standard tools.
Enough space should be provided around
the pad to ensure easy maintenance
activities.

Fig 7: preventive maintenance

Thank you for your

attention