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Process of Brake pads manufacturing
2. Mixing: The selected materials are mixed together in a specific ratio to form a homogeneous mixture. This mixture is often referred to as the brake pad compound.
3. Molding: The brake pad compound is then molded into the desired shape using high-pressure molding techniques. This process helps to give the brake pads their final shape and structure.
4. Curing: The molded brake pads are then cured at high temperatures to strengthen the bond between the different materials and improve their overall performance.
5. Finishing: After curing, the brake pads undergo various finishing processes, such as grinding or chamfering, to ensure smooth surfaces and proper fitment.
1. Friction and wear characteristics: Look for compounds that provide the desired friction and wear properties for efficient
braking. The compounds should be able to generate adequate braking force without excessive wear on the brake pads or rotors.
2. Temperature resistance: Brake pads can reach high temperatures during braking, so it's important to select compounds that can withstand these elevated temperatures without losing their friction performance or degrading.
3. Noise and vibration control: Consider compounds that have good noise and vibration damping properties to minimize brake squeal and vibrations, leading to a quieter and smoother braking experience.
4. Environmental impact: Select compounds that are environmentally friendly and comply with regulations, such as low levels of hazardous substances and low emissions of pollutants during braking.
5. Manufacturing compatibility: Ensure that the selected compounds can be easily processed during the manufacturing process and are compatible with the molding and curing techniques used for the production of brake pads.
6. Cost-effectiveness: Compare the cost of different compounds and consider the balance between performance and cost to ensure the selected compounds offer good value for money.
The mixed raw materials commonly used in brake pad production:
1. Metal-less Formula:
The metal-less brake pad formula is typically designed for low noise, low dust, and optimal braking performance.
The mixed raw materials used in metal-less brake pads often include:
Organic fibers: Organic fibers, such as Kevlar or carbon fibers, are commonly used to provide excellent friction and wear properties while minimizing noise. These fibers also offer good heat resistance.
Fillers: Various fillers, like reinforcing agents and friction modifiers, are added to enhance the brake pad's performance. Some common fillers used are graphite, ceramic particles, and rubber particles.
Resins: High-performance organic resins, such as phenolic resins, are utilized as binders to hold the mixed raw materials together and provide strength to the brake pad.
2. Semi-metallic Formula:
Semi-metallic brake pads are known for their excellent braking performance and durability. The mixed raw materials used in semi-metallic brake pads often include:
Metal fibers: Steel, copper, or other metal fibers are added to the brake pad mix to improve its strength and heat dissipation properties. These metal fibers also enhance the brake pad's performance at high temperatures.
Fillers: Fillers like graphite, iron, and other metal or ceramic particles are used to enhance the braking performance and wear resistance of the pad.
Friction modifiers: Friction modifiers, such as resins and lubricants, are added to the mix to optimize the friction
characteristics and reduce noise and vibration during braking.
Binders: High-quality binders, typically phenolic or synthetic-based resins, are used to provide cohesion and bonding between the mixed raw materials.
3. Ceramic Formula:
Ceramic brake pads are known for their exceptional braking performance, low noise, and minimal dust generation. The mixed raw materials used in ceramic brake pads often include:
