IJSRD - International Journal for Scientific Research & Development| Vol. 5, Issue 06, 2017 | ISSN (online): 2321-0613 All rights reserved by www.ijsrd.com 760 Design and Experimentation of Test Rig for measuring Effectiveness of Brake Pad Miss. Snehal R. Tantarpale 1 Prof. M. K. Wasekar 2 Dr.M.P.Khond 3 1 ME Student 2 Assistant Professor 3 Associate Professor 1 Department of Automotive Engineering 2 Department of Mechanical Engineering 1,2 SAE, Kondhwa, Pune (M.S), (India) 3 College of Engineering, Pune (M.S), (India) Abstract— Design and experimentation of test rig for measuring the effectiveness of brake pad aimed at estimating the performance of brake pad of a bike under numerous braking conditions and there by assist in the disc project and analysis. The test rig is equipped with several measuring instruments, and data acquisition systems [DAQ], which are necessary for performing the tests. Two sets of brake pads are tested. Optimized brake pads with hatched surface are suggested as it will dissipate more heat and increase its effectiveness. An analysis into practice of new materials is essential which improve braking efficiency and provide better stability to vehicle. We used two alternate materials fly ash and c-c composites. This investigation is done using ANSYS software along with the modeling software CATIA V5.Analysis done on real model of disc brake rotor of Bajaj pulsar 180 and rotor of different materials. Therefore, it gives optimize stress, deformation & weight of the improved disc brake rotor & also good heat dissipation. Key words: Brake disc, Rotor, Thermal analysis, PRO-E, ANSYS software I. INTRODUCTION In design optimization problem there are aims and limitations that must be met. With mechanical design, size, weight, strength, and cost are a few of the many restraints that may need to be taken into concern when designing for a set of objectives. Two sets of brake pads are tested. Optimized brake pads with hatched surface are suggested as it will dissipate more heat and increase its effectiveness. Hatched pads are hatched in inclined way. Hatch pads increase the friction and are more efficient than the existing brake pads. Temperature is reduced due to hatching as it provides ventilation between the brake pads, and gives us the better results. Altered materials fly ash and c-c composites for disc rotor are compared with the current material. These materials are compared and analyzed using present model, from which the best solution is chosen. The best material is then enhanced upon iteratively. These iterations are in essence series of trial and error that can regularly need many cycles, each of which can be expensive and time consuming. With finite element analysis and optimization, other difficult problems can be solved more rapidly, reducing the amount of physical testing for a new material. This helps address the cases whereon-optimal projects might carry on to be used to cut the time, cost, and danger of trying to find a better design. FEA methods are used to make disc brake rotor with material which is lighter and gives good results than the current rotor. The analyses will be taken with the help of sensors which are more accurate than manually taken results. II. LITERATURE SURVEY An Experimental Brake Pad Test Rig was designed and constructed using readily available materials. The equipment was designed to test automobile disc brake pad wear and effectiveness at various speeds and braking forces. To determine its functionality a wear test was conducted on a commercial brake pad at various speeds and brake forces. This prototype test rig can be used in testing the brake pad of different vehicle such as Toyota, Mitsubishi, Volvo, Peugeot, and other brands of interest. [1] This study describes an inertial dynamometer system (test rig) which has been applied to the testing of disc brake pads at different operating conditions. The test rig is equipped with several measuring instruments, and data acquisition systems [DAQ], which are necessary for performing the tests. Two sets of brake pads are tested. This study explains the temperature distribution obtained by experiments on two different shapes of brake discs pads affected by the types of shapes of brake discs pads, disc geometry and operating conditions. The test results also showed that the friction with hatched pad better fades resistance than the others. [2] Transient Thermal and Structural Analysis of the Rotor of Disc Brake is aimed at evaluating the performance of disc brake rotor of a bike under severe braking conditions and there by assist in disc rotor design and analysis. An investigation into usage of new materials is required which improve braking efficiency and provide greater stability to vehicle. [3] This work is presented with “Design modification & optimization in stress, deformation & weight of Disc brake rotor” which studies about on disc brake rotor by modeling & analysis of different shapes of slots of different vehicle’s disc brake rotor with same outer diameter & inner mounting position of holes on wheel hub as like Bajaj Pulsar 150.Analysis done on real model of disc brake rotor of Bajaj pulsar 150 and disc brake Rotor of different shapes of slots of different vehicle’s in one Disc brake rotor [4] This study incorporates the FEA and EMA analysis of squeal which is disc brake rotor of Cast steel material, the different parameters which are responsible for squeal in the braking system have been analyzed with the help of experimental modal analysis for Free-free condition and FEA is done with their boundary conditions. “Brake squeal” means noise occurs when the speed of the vehicle is below 30km/h and braking pressure is below 2Mpa, which radiates the noise in 1 kHz to 16 kHz audible frequency range. [5] By applying brake, shoe pad is grip the disc of disc brake due to that stopping of their rotation and altering kinetic energy in to Heat energy due to speedily apply handbrake there is thermal stress produce of disc. [6]