Friction materials play an important role in the brake system since brakes use friction to brake (decelerate and stop)

Brake pads and brake linings are made from a blend of no less than 10 to 20 kinds of raw materials. Blending the right materials for the required condition and performance is a highly complicated task requiring specialized know-how, which include leading-edge expertise of Discy Lent

The quality of a friction materials also change according to manufacturing process. With the development and manufacturing technologies refined over the years, Discy Lent offers high performance and high quality friction materials which meet our customers’ needs

Disc brake pads and drum brake linings are made from a blend of 10 to 20 kinds of raw materials. Depending on their specific roles, the raw materials are divided into three categories; “bonding material”, “stiffener”, and “friction adjustment material”

The bonding-material hardens raw materials and gives the materials their intensity. Mainly phenol resin is used currently

The stiffener gives the friction materials further intensity. Various kinds of organic and inorganic fibers, such as aramid fibers and metal fibers, are used

The friction adjustment material mainly adjusts the effectiveness of friction materials. It is used for strengthening the effectiveness or stabilizing the performance of friction materials. Various raw materials, such as a lubricants, organic fillers, inorganic fillers, abrasive material, and metal powder, are blended as necessary

摩擦材原材料

摩擦材原材料配合図

Furthermore, friction materials are required to exercise stable effectiveness (minimum fluctuation of effectiveness) under varying conditions, such as vehicle speed, laden weight, or temperature change from brake usage, as well as under different environmental influences including humidity, water, and mud. Strength to withstand thermal disturbances, and mechanical strength are also important design criteria

Durability is another important property of friction materials as they wear with use. Moreover, when brakes are applied, squeal, noise and vibrations must be minimized. Furthermore, the friction materials should not cause damage to the material they get into contact, such as the disc rotors. Friction materials also require to have low thermal conductivity to prevent temperature buildup of the brakes themselves or brake oil

Main performance requirements for friction materials are;

  • Optimum effectiveness, i.e. appropriate friction coefficient (μ)
  • Stable effectiveness under various usage and/or environmental conditions
  • Strength to withstand thermal disturbances, and mechanical strength
  • High level of durability

  • Minimized brake squeal, noise and vibrations
  • Low damage to the contact material, such as the disc rotor
  • Low thermal conductivity

For passenger cars, generally “non-steel” brake pads are used because of its balanced performance between effectiveness, intensity and resistance to brake squeal

For the development of friction materials, performance as well as quality that assures a long service life must be taken into consideration. This is realized by finding the right combination of raw materials as well as by optimizing the production conditions. There are many steps that must be taken before a product is delivered to our customers. It may take a few months or even a few years to complete this process. Physical and chemical properties of friction materials are evaluated. A test instrument called the dynamometer and Chase Machine, on which an actual brake can be fitted, is used to evaluate the friction properties. Actual cars are used to evaluate compatibility between car and brake. We are also developing raw materials which minimize environmental impact

Friction materials are manufactured through production, inspection and testing processes before they are manufactured

ブレーキバッド製造工程図

In the development of friction materials where various performance requirements must be met, how to blend different raw materials effectively is one of the most important technological expertise. How the materials are manufactured also influence quality, so production technology is also important

For the inspection and test processes of the friction materials, various methods are employed to check their quality. The processes include the evaluation of physical properties such as the hardness and intensity of the friction materials, as well as chemical analysis of organic materials

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