World J of Engineering and Pure and Applied Sci. 2012;2(3): ): ): ):92 92 92 92 ISSN 2249-0582 Bashar Bashar Bashar Bashar et al et al et al et al., 2012. Production of Cold-Worked Brake Pad OPEN ACCESS © Research | Reviews | Publications, 2011 http://www.rrpjournals.com/ OPEN ACCESS Original Original Original Original Article Basic Science Material Selection and Production of a Cold-Worked Composite Brake Pad Bashar DAN-ASABE 1 , Peter B MADAKSON 1 , Joseph MANJI 2 ABSTRACT [ENGLISH/ ABSTRACT [ENGLISH/ ABSTRACT [ENGLISH/ ABSTRACT [ENGLISH/ ANGLAIS ANGLAIS ANGLAIS ANGLAIS] Affiliations: 1 Shell Chair Office, Department of Mechanical Engineering, Ahmadu Bello University, ZARIA 2 Depa Department of Mechanical Engineering, Ahmadu Bello University, ZARIA Address for Correspondence/ Adresse pour la Correspondance: bashar.danasabe@gmail.com Accepted/Accepté: February, 2012 Citation: Bashar DA, Peter BM, Joseph M. Material selection and production of a cold- worked composite brake pad World Journal of Engineering and Pure and Applied Sciences 2012;2(3):92-7. This paper entails the selection and production of composite brake pad with varied constituent’s composition. Series of tests were conducted that involved tensile, compressive, hardness, impact, wear and corrosion to ascertain composition with the best property as compared to a commercial Honda brake pad (Enuco) model widely used in Nigeria. The results shows that higher percentage of grounded coconut shell powder induces brittleness since compositions with lower percentage of it produced higher breaking strength and lower wear rate. It was also established from the tests results that compositions 4 and 5 have an overall better mechanical and corrosion resistance property than the model with composition 4 having the least wear rate effect. Keywords: Material selection; cold-worked brake pad; mechanical tests RÉSUMÉ RÉSUMÉ RÉSUMÉ RÉSUMÉ [FRANÇAIS FRANÇAIS FRANÇAIS FRANÇAIS/FRENCH /FRENCH /FRENCH /FRENCH] Ce document comporte la sélection et la production de plaquette de frein compositeavec une composition variée de constituant. Des séries de tests ont été effectués à la traction que parties concernées, à la compression, la dureté, l'impact, l'usure et la corrosion de la composition de vérifier avec le meilleur des biens par rapport à un padcommerciale Honda de frein (Enuco) modèle largement utilisé au Nigéria. Les résultats montrent que pourcentage plus élevé de la noix de coco en poudre à la terre enveloppeinduit une fragilité depuis compositions avec plus faible pourcentage de celui-ci produitune plus grande résistance de rupture et de baisse du taux de l'usure. Il a également étéétabli à partir des résultats des tests que les compositions 4 et 5 ont une propriété de résistance mécanique et une meilleure globale à la corrosion que le modèle avec la composition 4 ayant le moins d'effets taux d'usure Mots-clés: La sélection des matériaux; écroui plaquette de frein, les tests mécaniques INTRODUCT INTRODUCT INTRODUCT INTRODUCTION ION ION ION Development of frictional composite brake pad of lighter weight, improved mechanical properties and corrosion resistance capability is essential in minimizing cost, material and wear while improving the safety on our high ways. The significance of brake pad is to transform the kinetic energy of a vehicle to heat energy via friction and ejecting the heat to the surrounding environment. Drum (shoe) brake and disk (pad) brakes are the major types of friction brakes. Most of the brake pad material constituents are composites of varied material constituents. There are more than 2,000 different materials and their variants are used in commercial brake components [1]. The first frictional brake material composed of cotton material impregnated with bitumen solution was invented by Herbert Frood [2] in 1879. This led to the establishment of Ferodo Company that still supplies brake pad materials up till now. Table 1 lists some of the common brake pad materials. Composite brake pad constituents’ materials are composed of varied composition of abrasives, friction modifiers, binders, fillers and reinforcements. These are explained by Hooton [1], Spurr [3], Rhee [4], Hoeganaes [5], Nicholson [6], Gudmand-Hoyer et al [7], Borden [8] and Jang et al [9] as summarized in the Table 2. Medical research has shown that asbestos usage can induce adverse respiratory conditions. Asbestos is still in use because of its high strength fibre and cheapness but its gradually phasing out due to respiratory problems it causes in the human lungs [1]. MATERIALS AND METHODS MATERIALS AND METHODS MATERIALS AND METHODS MATERIALS AND METHODS This involves selection of constituents’ materials, production of the brake pad with varying composition and carrying out mechanical and chemical test.