Name: Rajib Dutta

Roll: ME19S007
Course: Engineering Design with
Polymers(ME5525)
Guided By: Dr. Gnanamoorthy,
R.
1. Design a polymer matrix 2 wheeler front
brake pad for 150 CC motorbike. Assume
possible operating conditions, dimensions,
materials and design. Estimate the wear
thickness after 1 year of use. Assume 5
hours per day, average speed 40 kmph,
approx 50 times of brake application per
day.
Brake Pad Material
• Binder
• Pheonic resign often used as binder material, because of excellence heat resistance
• Fillers
• Barium sulphte, cashew dust, calcium carbonent, rubber, vermiculite, brass
• Metal
• Cu dust, addition of metals to high heat transfer
• Fibers
• Organic fibers, carbon fibers,aramid,steel,glass

• Friction Modifiers:
• Graphite, aluminum oxide

• Reinforced fibers.
• The reinforced fibers are used to improve friction performance and strength. The metal fibers (iron, copper, etc.), glass fibers,
carbon fibers, and organic fibers (Kevlar, cotton, etc.)
Dimension
• Brake Pad outer radius : 123mm-130mm
• Brake pad Inner radius :100mm-105mm
• Contact area: 8315 mm2 to 9228 mm2
• Thickness: 16mm-18mm
• Width: 53-60mm
Wear Calculation
• Wear thickness depend on various factors
• Sliding velocity
• Contact Pressure
• Braking Torque
• Stopping Distance
• Coefficient of friction
• Braking time
•  According to Rhee
• The wear of automobile brake pad is
• Where , contact pressure (Pa), slide rate (m/s),time(sec)

• Assuming 5 hours per day, and 50 times a day

• So Average braking time=

Specific Wear rate 1.78*10-13 (Jang et al, 2004 )

Contact Pressure 1*10 6 Pa
Sliding Velocity 40kmph = 11.1111m/s
Time 360 Sec
• 
meter
mm
so, mm, reduction on single time application of pad
So, in a year= 50 times per day*365=18250 times
• Another Approach
•  Frictional Force: , where F is the Normal force on the pad
• , where , are Cylinder wheel diameter, master cylinder diameter, Amplification factor of
pedal force, Pedal force, braking mechanical efficiency
• Breaking Torque = Effective rotor radius* Frictional Force
• Work Done= Breaking Torque*
• == Thickness loss

Wear of Friction Material during Vehicle Braking Shaoyang

Zhang, Weiping Chen and Yuanyuan Li South China University
of Technology
 2. The rectangular plate of dimension 50mm x 40
mm and thickness 30 mm has to be made using PLA
polymer.  A rectangular hole of dimension 5 x 5 mm
passes through along the 50 mm side direction at the
center. Design the part for AM, and fix the suitable
layer thickness and other parameters
A rectangular plate of 50m x 40mm x 30mm has a central hole of 5mm x 5mm
pass through along the 50 mm side at center

Material Specification:
Material: PLA
Working Temp: 1800C- 2200C
Print Bed Temp: 800C- 1100C
• We Know For additive manufacturing we have to first create a .stl file
• From a CAD software then we have feed the .stl file to Additive
manufacturing software

CAD/CAM Create a 3D FDM

Software Model Printer Software

Create G-Code Slicing into Control Print Parameter

Like: Layer height, Support, Infill
and M-Code layers Percentage

Post
Print Final Product
Processing
Parameters
• Nozzle dia Selection
• Print Head temperature
• Print bed temperature
• Infill percentage
• Layer height
• Support material required or not
• In Additive manufacturing while printing process the orientation of
the object plays an important role,
• In our case the object is a rectangular plate with a rectangular slot
• So, let, L,W,H are length, width and height of the object, so the base
can be represented by 3 distinct ways,
• LXW
• LXH
• WXH
 Case 1 Case 2

40mm
50mm

30mm
Side View

50mm
Front View
30mm

40mm

30mm
Base: 40mm x 30 mm Base: 50mm x 30 mm
Top View Top View
 Case 3

30mm

40mm
Side View

50mm
40mm

Base: 50mm x 40 mm
Top View
Print Time
•As  additive manufacturing process is layer by layer addition process so,
Print time = function(layer height, nozzle diameter, height of print object, etc.)

As we can see in case 1 height of print block is 50 mm, in case 2 height

of print block is 40 mm and in case 3 height of print block is 30 mm,
We can collude that keeping other parameter constant ,

>>
Case 1
• As Showed in case 1 the height of specimen is large, so more time it
will take to print,
• But, The tool in air movement will be less than other two, so stringing
and bridge formation will become less
• No support material will required
• Minimum post processing will be required
Case 2 and Case 3
•  Case 2 and Case 3 has similar will have similar type of observation,

• As the Height is less than the case 1 hence time to compete the job
will be less, but >

• For both cases the tool in air movement is larger than case 1 so bridge
will form while printing, which requires post processing to clean

• Siring formation will be more in case 2 and case3

Infill Percentage
• The infill percentage is directly proportional to the strength of the
object
• More infill percentage more material will required, mass pf the
component will more of more infill percentage
Layer Height
• More Layer height will cause the texture of the surface irregular, and
lead to a bad surface finish
• The Staring affect will become less more least layer height
• In additive manufacturing process the next layer always suppress the
previous layers, so more layer height will deform more
• Layer height also depends upon the Nozzle dia