Description
INTRODUCTION
FIG DISC BRAKE ROTOR
FIG DISC BRAKE ASSEMBLIES
PROJECT LOACTION-HOSUR
CLIMATE
TRANSPORTATION
ROAD
RAIL
HOSUR RAILWAY STATION
AIR
MAIN REQUIREMENTS OF BRAKE
THE ACTUAL STOPPING DISTANCE OF VEHICLE WHILE BRAKING DEPENDS
ON THE FOLLOWING FACTORS:-
LASSIFICATION OF BRAKE SYSTEM:
1. ON THE BASIS OF MODE OF ACTUATION:
2. ON THE BASIS OF MODE OF OPERATION
3. ON THE BASIS OF ACTION ON FRONT OR REAR WHEELS
4. ON THE BASIS OF METHOD OF APPLICATION OF BRAKING CONTACT
B) TYPES OF BRAKE SYSTEMS
PARKING BRAKES
EMERGENCY BRAKES
ANATOMY OF A PAD
RAW MATERIALS
BRAKE PADS/SHOE MADE OF:-
BINDER (MATRIX) MATERIALS
ABRASIVE MATERIALS
FRICTION PRODUCERS / MODIFIERS
FILLERS, REINFORCEMENTS, AND MISCELLANEOUS
BRAKE MATERIALS AND ADDITIVE FUNCTIONALITY
ONE CAN GROUP BRAKE MATERIALS AND ADDITIVES BASED ON THEIR EXPECTED
FUNCTIONS AS FOLLOWS:
ABRASIVES
FRICTION PRODUCERS / MODIFIERS
FILLERS, REINFORCEMENTS, AND MISCELLANEOUS
BINDER (MATRIX) MATERIALS
BRAKE FRICTION DESIGNATIONS AND TYPICAL COMPOSITIONS
SAE RECOMMENDED PRACTICE J866A LISTS THE FOLLOWING CODES
AND ASSOCIATED FRICTION COEFFICIENTS:
ACCORDING TO COMMERCIAL LITERATURE THERE ARE SIGNIFICANT
LIMITATIONS REGARDING THE USE OF SAE EDGE CODES:
FORMULATION TREND
BRAKES ARE NOW MANUFACTURED FROM A VARIETY OF DIFFERENTMATERIALS
THAT MAY BE:
ASBESTOS PADS
SEMI-METALLIC PADS
NON-ASBESTOS ORGANIC PADS
LOW STEEL PADS
CARBON PADS
FORMULATION
BRAKE PAD
BRAKE LINING
FACTOR EFFECT THE DEVELOPMENT OF FRICTION BY THE BRAKE SYSTEM
BRAKE FADE
BREAKS ARE DESIGNED TO FADE.
OTHERS FACTORS THAT AFFECT THE OPERATION OF BRAKE SYSTEM
WEIGHT TRANSFER
WATER ON BRAKE LININGS
CHARACTERISTICS
BRAKES ARE OFTEN DESCRIBED ACCORDING TO SEVERAL CHARACTERISTICS
INCLUDING:
DISCS
ON MOTORCYCLES
A DRILLED MOTORCYCLE BRAKE DISC
ON BICYCLES
A MOUNTAIN BIKE DISC BRAKE
RACING
CERAMIC COMPOSITES
CERAMIC DISCS ARE USED IN SOME HIGH-PERFORMANCE CARS & HEAVY VEHICLES
BRAKE COMPONENTS
THIS LIST INCLUDES:
MAIN COMPONENTS OF A DISC BRAKE
VARIOUS PARTS OF DISC BRAKE
BRAKE ROTOR OR BRAKE DISK
SIZE OF ROTOR/DISC:
WHY LARGER DISC PROVIDES BETTER BRAKING?
TYPE OF DISC BRAKES
CROSS DRILLED ROTOR
THE MAIN ADVANTAGES OF THIS TYPE OF ROTOR ARE:
THERE ARE FEW DISADVANTAGES AS WELL
CROSS SLOTTED ROTORS
ITS ADVANTAGES ARE AS UNDER:
DISADVANTAGES:
PETAL ROTOR/WAVE DISK
ADVANTAGES OF PETAL DISCS:
THERE IS ONLY ONE MAJOR DISADVANTAGE OF THIS KIND OF DISC THAT IT
WEARS OUT THE PADS AT A FASTER RATE
DAMAGES CAUSED TO THE ROTOR
DRUM BRAKES-DETAILS
COMPONENTS
BACKING PLATE
BRAKE DRUM
WHEEL CYLINDER
BRAKE SHOE
IN OPERATION
NORMAL BRAKING
AUTOMATIC SELF-ADJUSTMENT
EMERGENCY BRAKE
ADVANTAGES
TO LIST ADVANTAGES OF DRUM BRAKES:
DISADVANTAGES
DISC BRAKE- DETAILS
COMPONENTS
BRAKING DISC
CALLIPERS
PISTONS AND CYLINDERS
BRAKE PADS
BRAKE SQUEAL
BICYCLES
ULTRA SONIC PROCESS AND SHOT BLASTING
ULTRASONIC CLEANING
TUMBLE SHOT BLASTING
FOR BETTER SHEAR COVERAGE – CONVEYOR SHOT BLASTING IS ALSO PREFERABLE
MANUFACTURING PROCESS (BRAKE PAD)
HOT PRESSING MACHINE
OVEN CURING
SURFACE GRINDING
SCORCHING
POWDER COATING
GAS FLAME TREATMENT
SHIM BONDING & PRESSING
FINISHING ASSEMBLY OPERATION
CODE PRINTING MACHINE
BRAKE PAD PRINTING MACHINE IS EQUIPMENT TO PRINTING INFORMATION
ON BACK SIDE OF BRAKE PADS,LIKE LOGO,BRAND,AND PART NUMBERS AND SO ON.
DOCK AUDIT
VERIFICATION OF DIMENSION
VISUAL INSPECTION
PACKAGING
PRODUCT TEST REPORTS
MANUFACTURING PROCESS (BRAKE SHOE)
TESTING OF PHYSICAL PROPERTIES FOR FRICTION MATERIALS
MIX TESTING
MOISTURE TESTING
BACKPLATE ROUGHNESS TESTING
BACK PLATE GLUE THICKNESS
GOGAN HARDNESS TESTING
DENSITY & POROSITY
ACETONE EXTRACTION
SHEAR STRENGTH TESTING
POWDER COATING TESTING
SALT SPRAY TESTING
SHIM BONDING TESTING (T-PULL)
MARKET POSITION
CHINA AND INDIA TO HOLD SIGNIFICANT SHARE OF GLOBAL TWO-WHEELER
BRAKE PADS MARKET
KEY PLAYERS OPERATING IN GLOBAL MARKET:2
MARKET, BY VEHICLE
MARKET, BY MATERIAL
MARKET, BY SALES CHANNEL
MARKET, BY POSITION
BRAKE SHOE MARKET: MARKET PARTICIPANTS
CUSTOMERS AND COMPETITORS
CUSTOMERS
MAJOR CUSTOMERS
A LIST OF 2W DISC BRAKE PAD
PROCESS FLOW DIAGRAM-BRAKE PAD
PROCESS FLOW DIAGRAM-BRAKE LINING
RAW MATERIAL
STAMPING
WELDING
HOT PRESSING
BONDING
GRINDING
RIVETING
DOCK AUDIT
PACKING
RAW MATERIAL PHOTOGRAPHS
BINDER
ABRASIVES
FRICTION PRODUCERS / MODIFIERS
FILLERS, REINFORCEMENTS, AND MISCELLANEOUS
MACHINERY PHOTOGRAPHS
BRAKE PAD
ULTRASONIC CLEANING
MULTI-FUNCTION MIXER
AUTOMATIC MATERIAL MIXING SYSTEM
BRAKE PAD FRICTION MATERIAL MIX MACHINE
GLUING MACHINE
POWDER COATING MACHINE
DUST COLLECTING SYSTEM
HOT OVEN MACHINE
SCORCHING MACHINE
RIVETING MACHINE
SLOT AND CHAMFER MACHINE
GRINDING MACHINE
COMBINED GRINDING MACHINE
6 WORKTABLES HOT PRESS
AIR COMPRESS MACHINE
BRAKE SHOE MANUFACTURING
STAMPING
WELDING
HOT PRESSING
BONDING
GRINDING
RIVETING
PACKING
PRODUCT PHOTOGRAPHS
APPENDIX – A:
1. COST OF PLANT ECONOMICS
2. LAND & BUILDING
3. PLANT AND MACHINERY
4. FIXED CAPITAL INVESTMENT
5. RAW MATERIAL
6. SALARY AND WAGES
7. UTILITIES AND OVERHEADS
8. TOTAL WORKING CAPITAL
9. COST OF PRODUCTION
10. PROFITABILITY ANALYSIS
11. BREAK EVEN POINT
12. RESOURCES OF FINANCE
13. INTEREST CHART
14. DEPRECIATION CHART
15. CASH FLOW STATEMENT
16. PROJECTED BALANCE SHEET
