Manufacturing process of

Brake Lining
By G.Durga Nagendra Kumar
Main objective of this session
• To create awareness on brake lining manufacturing process
• Main function of brake lining.
• Working principle of brake lining.
• Friction material composition & material properties.
• Main conclusion of each process.
 What is Brake lining
A brake lining is friction material attached to the face of
a brake shoe, to cause frictional force when the brake shoe makes
contact with the brake drum. A brake lining can be bonded or riveted
to a metal brake shoe.
What is Brake friction material
• The friction material in a brake system is a multiphase
composite containing more than ten ingredients and is
considered one of the most complicated material systems.
This is because the brake friction material must be developed
to sustain brake performance in a wide temperature range and
designed to moderate friction-induced excitation at the sliding
interface by proper material design.

Function of Brake lining

• The primary function of a brake lining is to slow or stop the
motion of a machine or vehicle (car, truck, train, motorcycle,
etc..).
Brake lining in all types of vehicle’s
2-Wheeler

Trains
Brake linings in all types of vehicle’s
• Passenger car vehicle’s Light commercial vehicle’s

Heavy passenger & commercial vehicle’s

 Main principle of brake lining
Braking of the vehicle depends upon the static function that acts between tyre’s
& road surface.

Brake work on the following principle to stop the vehicle :

“The Kinetic energy due to motion of the vehicle is dissipated in the form of heat
energy due to friction between moving parts (wheel or wheel drum) and
stationary parts of vehicle (brake shoes)”.

The heat energy so generated due to application of brakes is dissipated into the
air.

Brake operate most effectively when they are applied in a manner so that
wheels do not lock completely but continue to roll without slipping on the surface
of the road.
Main principle of brake lining
When you’re gauging a brake pad, it’s important to keep its coefficient
of friction in mind.

What coefficient of friction?

Coefficient of friction: it is the ratio of friction force between two

façades and the force that’s pushing them together.

A coefficient of friction is a value that shows the relationship

between the force of friction between two objects and the normal
reaction between the objects that are involved. It is a value that is
sometimes used in physics to find an object's normal force
or frictional force when other methods are unavailable.
 Manufacturing process flow of Brake Lining
Mixing

Preforming

Curing

Baking

Finishing

Gang saw Edge Trimming ID & OD Wear

Drilling Chamfering
cutting by grinding grinding Marking
Mixing
• The friction material's used in mixing process of brake lining
are
S.No Material details Range
1 Asbestos fiber 5 - 30%
2 Phenolic resin 10 - 45%
3 Barium sulphate 0 - 40%
4 Cashew particles 3 - 30%
5 Graphite 0 - 15%
6 Metal sulphides 0 - 8%
7 Abrasives 0 - 10%
8 Friction dust 0 - 20%
Mixing : Properties of each material
Asbestos fiber :
Chrysotile asbestos, the main constituent in most friction products, other types of asbestos.
Asbestos is hydrated magnesium silicate Mg$Si205 (OH)d. When it is used, the content of asbestos in
vehicle brakes varies between about 30-70%.
Main important characteristics of Asbestos fiber are
(1) Asbestos is thermally stable to 500°C above which it produces silicates
(2) Asbestos helps regenerate the friction surface during use
(3) Silicates produced by asbestos are harder and more abrasive that asbestos
(4) Asbestos insulates thermally,
(5) It processes well & it wears well,
(6) It is strong yet flexible, and
(7) Asbestos is available at reasonable cost. The fibrous character remains in tact until about 14OO’C.
Mixing : Properties of each material
• Phenolic resin : Phenolic resins is used
as binders in brake lining which provide
superior heat resistance, good flexibility,
high mechanical strength and good friction
properties.

• Barium sulphate :Barium sulfate(or barium

sulphate) is a white crystalline solid . It is
poorly soluble in water and other traditional
solvents but is soluble in concentrated
sulfuric acid.
Mixing : Properties of each material
• Cashew particles : Cashew Friction Dust
Particles decompose on the surface of a
lining at various elevated temperatures
which controls the wear and offers a
protective device by prohibiting excessive
temperature from being developed. They
have a resilient nature which cushions the
engaging property of a piece of lining.
Graphite :Graphite and carbonaceous
raw materials are used as friction modifiers
for balancing cohesive and adhesive
frictional forces. These materials cushion
friction particles to optimize stopping
performance and pedal feel.
Mixing : Properties of each material
• Abrasives : Abrasive is a material, often
a mineral, that is used to shape or finish a
workpiece through rubbing which leads to
part of the workpiece being worn away by
friction.
• Friction dust: Friction dust is a granular,
brown or black color, free flowing
polymerized resin. Brake manufacturers can
choose the most appropriate friction dust
material from a broad range of mesh sizes and
granulation to be used in metallic, semi-metallic
and non asbestos brake products.
Mixing process description
• All these above material are combined together in sequential
order with subsequent engineering ratio in cylindrical shape
mixer.
• Cylindrical shape mixer contains cutters (3-4 cutters) & shovel,
which are required to produce homogenous mixture by the
combination all materials, And this cutters and shovel are
continuously running throughout mixing process.
• Mixing process consists of multiple mixing cycles with
different range of cutter & shovel rpm.
• Usual range of cutter RPM in all cycles is “1000 – 2000 RPM”
• Usual range of shovel RPM in all cycles is “100 – 150 RPM”
Cutters & shovel arrangement inside the cylindrical mixture

Cutters
shaft

Cutters

Shovel
motor shaft

Shovel

Cylindrical
container
Mixing process out come

Friction material
mix batch
Mixing process : In process inspection
• Bulk density :Weight of a unit volume of a
friction material to the same volume of water.
Expressed in kilograms per cubic meter (kg/m3)
or pounds per cubic foot (lb/ft3), it is a type of
relative density and is used mainly in quality
control, shipping, and soil analysis.
Mix moisture : Static coefficient of friction
increased with increase in moisture content
for all the surfaces. This is due to the increased
adhesion between the grains and the material
surfaces at higher moisture values.
Preforming process
• Mix weight of 0.5kg to 1 kg is taken and poured in cavity of
compression die mould of hydraulic press & Hydraulic
pressure of 15 to 16 MPa is applied for around 8 minutes