ABSTRACT
This report presents the development of light vehicle brake pad test rig for testing and measuring the materials frictional characteristics such as brake pad wear rate, disc temperature, and average disc stopping time. Product validation and quality control is very necessary in the developmental process of any product. The brake pads were tested at various input variables such as speed and pressure to determine the effects of contact pressure on brake pad wear, and effects of speed on brake pad wear, disc temperature, and average stopping time. Two sets of brake pads designated as pad1 (Semi Metallic pad) and pad2 (Ceramic pad) were tested. At maximum disc speed (1400 rpm) and contact pressure (0.8 MPa), the wear rate of pad1 is 4×10-4 mm while pad2 is 4.12×10-4 mm both of which are lower than 5×10-4 mm as reported by Blau, 2001. On varying the contact pressure, the wear rate of pad1 and pad2 at (0.8 MPa) are 3.9×10-4 mm, 4.0×10-4 mm respectively, and at (1.4 MPa) are 4.3×10-4 mm and 4.4×10-4 mm respectively. It was discovered that the wear rate increase as brake applied pressure increase. The pad2 ceramic brake pad takes least time to stop on the average. On the average the disc temperature rise at any speed shows that pad1 have high temperature rise in comparison with pad2 which makes pad2 a better brake pad.
CHAPTER ONE
1.0Â INTRODUCTION
1.1 Background to the Study
The utilization of motor vehicles as among other means of shipping on roads and other compliant surfaces cannot be over stressed and has been an essential component of daily performances. An important reflection for secure, successful function and restraint of these motor vehicles is the braking mechanism which must be capable of slowing down the vehicle at a quicker rate than the engine can speed it up (Aderibigbe et al., 2016). The two varieties of braking mechanism are: the drum brakes and the disc brakes. Motor vehicle utilised either of the two braking system or both the drum brakes and disc brakes, the main parts of a disc brake are among other frictional brake pads, rotor, Â and calliper. The critical component of any braking mechanisms is frictional brake fabric. It is as a result critical to prove the activities of the frictional associate in laboratory tests and working trial ( Systemtechnik, 2017).
The activities of the frictional brake fabric must meet least desires for wear, sound and toughness (Deepika et al., 2013). Disc braking mechanism consist of brake pad frictional fabric that must be changed time to time after wearing (Deepika et al., 2013). The performance of braking mechanism is limited by factors such as driver attitude, vehicular utilization, brake pad fabrics, the terrain where the vehicle is being used, vehicle gross weight, and also among others the mal adjustment of brake calliper (Nwufo et al., 2013).
Vehicular kinetic energy is transformed to heat energy generated in brake mechanism within 5 – 15 s, which is the typical time taking when applying brake from a reasonable small speed to the full stoppage. Heat energy released between the surfaces in contact affect the brake performance (Hwang et al., 2008). Defects on the surface, which may be due to profile errors and geometric formation, may be the reason for uneven temperature distribution.
1.2 Statement of the Research Problem
The experimental brake pad test rig apparatus are scarce and expensive in nation like Nigeria. Therefore, development of inexpensive test apparatus using local material comes up. A lot of frictional engineering materials (specifically brake pads) are being developed in institutions of higher learning and needed to be tested for validation. This study centres on the developing brake pad test apparatus to cater for this demand and serve as sources of validating performance and durability of motor vehicle frictional brake pad by replicate the braking mechanism on which the pads are to be used.
1.3 Justification of the Study
Testing of engineering materials is a paramount step in any developmental process of products or experimental research in general. Developing countries like Nigeria are far behind in terms of product development making it difficult for researchers when verifying validity of the research carried out or testing the various properties of materials produced from various researches. This machine will serve as a means to fill this gap. Millions of dollars are being spent on buying of testing equipment and even test being sent to foreign countries by various researchers in institutions of higher learning across the country, the test rig being developed will be a source of furthering our own local content, improving home production industries thereby relieving difficulties faced by researchers.
1.4 Aim and Objectives of the Research
The aim of this research work is to develop and carry out performance evaluation of light vehicle brake pad test apparatus.
The objectives are:
1. To design a brake pad test rig
2. To fabricate a brake pad test rig.
3. To carry out performance assessment of the brake pad test rig.
1.5 Significance of the Research
Local manufacturing is the key to the industrial revolution needed in Nigeria. Validation and property control of any product is very vital in process of the product development. The product could be a machine or an engineering material. Today in our Nation research institutes, researchers have been working on frictional materials with a view to find a more reliable and competitive frictional materials with good frictional properties that could possibly replace the existing original equipment manufacturers (OEM) brake pad materials using local materials which needs testing. The method use for evaluation of these brake lining is through full vehicle test which is expensive, since this brake pad full vehicle test is expensive, it has become necessary to develop a laboratory method for quick, low cost and effective evaluation of brake linings for validation.
1.6 Scope of the Research
This work deals with the development of a brake pad testing apparatus to discover the effect of surface contact pressure on brake pad wear, effect of speed on brake pad wear, effect of speed on average stopping time of the disc and on disc temperature.
1.7 Limitations of the Research
Estimating some frictional properties of brake pad requires versatile apparatus such as vastly susceptible revolution measuring instrument, temperature measuring instrument, and brake applied pressure gauge which are rare and costly, some accessible apparatus for estimating brake pad frictional properties were utilized to accomplish the research objectives.
This material content is developed to serve as a GUIDE for students to conduct academic research
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