Developing light-weight 3D-printed brake-pad with internal geometry for low friction & wear

Syed Mohamad Junus, Syed Mohamad Syafiq (2022) Developing light-weight 3D-printed brake-pad with internal geometry for low friction & wear. Project Report. Universiti Teknikal Malaysia Melaka, Melaka, Malaysia. (Submitted)

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Abstract

In the automotive sector, we all know that the brake pad is a crucial component that functions as a mechanism to slow down or to stop the vehicle. Besides choosing the right material to be applied as friction material, the design of the brake pad in terms of optimal geometry also had to be considered as a factor of brake pad wear. Internal geometry plays a big role in any design including the brake pad. The purposed of this research to study the design of internal geometry that can produce low friction and wear toward the brake pad. There are a few methods that considered in terms of design that can make brake pads less friction and wear. In this project, the method was choosen was to applied certain pattern of geometry toward the surface of brake pad. The real brake pad has been chosen and drawn using CATIA V5R21software. The next process is to analyze the real brake pad design using SIMSOLID software and from that analysis, it will come out with the new geometry and dimension. From that drawing, the new brake pad replica is produced by using the 3D printing method or the be specific, those processes are using SLS machine. The analysis that been applied was normal traction, displacement magnitude, von mises stress and maximum shear stress. All of this analysis was been made find out which geometery pattern was the best in terms of less wear and friction.

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