COMPOSITE BRAKE PAD WITH BAGASSE FIBRE
Field of the Invention:
The present invention is related to automotive sector. I have developed a composite brake pad with bagasse fibre.
Description of the Related Art:
In automotive industries asbestos is most common material used in braking system, but it is banned in many of the countries because of its carcinogenic nature. Therefore many of the scientists focus to develop new material with.minimum cost which is eco-friendly. However, so many researches hopped to come up with equal efficient alterative material as asbestos and more than three thousand materials are available in market with different brand and each one has its unique properties. But no ones are able to replace asbestos with equal efficiency and low cost.
Summary of Innovation:
Objective of this research is to investigate a new eco-friendly material with low cost. Therefore we are focusing on developing new material with agricultural waste. Newly develop material composed of bagasse as a rainforcing fibre and calcium carbonate, silicon as an additive and epoxy resin as a binder having optimum strength and high coefficient of friction. As compare to asbestos, new material is having high friction coefficient and low wear rate with low cost.
In traditional brake pads, asbestos is widely used but it causes health risk. It causes asbestos related dieses like asbestosis, diffuse pleural thickening etc. In India there are crores of vehicles moving on road daily and each vehicle is equipped with braking system. As many out of these uses asbestos based brake pad materials, there is tremendous escape of asbestos fibers in environment from wear of brake pads. If such a thing continues, many people may get suffer from cancer or asbestosis. By keeping this adverse future situation in mind, here we tried to make a new asbestos free brake pad material which should exhibit the same remaining required

properties as asbestos and can be a good replacement for it. Asbestos free brake pad manufactured from bagasse fiber, has very low cost compare to asbestos fiber.
SAMPLE PREPARATION
Materials -
The materials used during the course of this work are:
1. Araldite Epoxy resin
2. Bagasse fiber
3. Calcium carbonate
4. Silica powder
Selection of material composition has been done by using some standard available
references according to the role of additives to control wear and friction.
Epoxy resin is used as a binder in composite brake pad using bagasse. Epoxy resin has
capacity to adhere most substances because of presence of polar hydroxyl and ether bond in it. It
has high mechanical strength (80 MPa) with minimum shrinkage that avoid compression.
Epoxy resin can also resist most of the chemical attacks and epoxy resin consider as water
tighten (i.e. moister resistance),
All researchers try to use locally available, light weight and inexpensive fiber. Also lots
of research is going on agricultural and industrial waste material. Bagasse is preffered here
because it has potential to use as a reinforcing matrix and currently India is largest sugarcane
producer in the world. In India only 10 % bagasse used in paper industries remaining 90%
bagasse is thrown as a waste or burn in air.
Calcium carbonate used as lubricating material in brake pad instead of graphite. It is
cheap and easily available. Also have good thermal stability.
Silicon used as an abrasive due to their properties such as heat resistance, Flame
retardancy, Chemical stability, water repellecy, good compression characteristics, cold resistance
etc.
Obtained Best Composition-Compression strength and hardness of brake pad increase with increase in resin. But
increased hardness also increases the brittleness, which causes wear of rotor. At 40% binder,
good binding of bagasse obtains. Silicon takes 10% of total percentage. If percentage of silicon

increases, it increases the hardness of brake pad and ultimately it increases the possibility of
wearing of the disk.
Prepare sample as per following composition -

Sr. no. Material Function
1. Araldite Epoxy resin
(45 % hardener + 55% resin ) Binder
2, Bagasse fibre Additive
3. Silica powder {CAS Number 7440-21-3) Abrasive
4. Calcium carbonate (CAS Number 471 -34-1) Fillers
DETAILED DESCRIPTION
Method of Sample preparation:-
1. The bagasse was dried in a sun light about one week after extracting a juice.
2. The dried bagasse was ground into powder using grinding machine.
3. The sieve grade analysis of the bagasse peels particles was carried out using Jayant Test Sieves, and separately prepared powder in different sieve size.
4. First prepared a binder by mixing resin with hardener (45 % hardener + 55% resin).
5. Then prepared second mixture of bagasse particle, calcium carbonate and silicon powder as per composition.
6. Then binder mixed with second mixture and prepared homogeneous mixture.
7. Such mixture filled in die and press using hydraulic press by regulating the pressure 100 KN/cm2 at NTP for 2 min. A die was prepared as per sample required for different test.
8. Removed the prepared sample from die and kept at NTP for curling. Brake pad sample was cured at NTP within 24 hours.
9. After curling, I removed material from die and prepared in required dimension using grinding machine.
Method of characterization-

4, Sieve analysis
2. Density
3. Flame resistance
4. Compression test
5. Shore d hardness test
6. Shear strength
7. Pin on disc
8. Oil socking and water socking
CALCULATION
1. Sleeve analysis result -
Sleeve analysis using Jayant sleeve analyser

Mesh No. % of Material retained
100 70,54
150 14.54
200 8.20
300 6.20
500 0.10
Ultimate Compression strength (Sut) of Pin - 55.87 N/mm2
using UTM, Test Method IS-1608-2005*
Shore D Hardness of pin - 74
.. .Hardness test by Durometer test method: - ASTM D2240 / DIN 53505 Thermal resistance -Ash content 23.65% heating 700 °C for 5 hrs.
.... (Ash content determine by chemical analysis.) Porosity -Porosity of sample 10%
.... (Under 100X Magnification according to IS-1608-2005) Shear strength - 6.53 N/mm2

Density calculation-Dimension of sample measure using Vernier calliper.

Sample no. Diameter Height Area Volume Weight Density
1 13 26 132.73 3451.03 4.22 1.22*UKJ
2 13.2 27.7 136.8477 3790.68 5.00 1.3*10"*
3 22.6 52 401.14 20859.79 23.82 1.14*10*
4 14.3 12.5 160.60 2007.575 3.62 1.80*10'3
Water Socking Calculation-Sample 1 -Effect on weight-Initial weight of sample -6.42 Final weight of sample after water soaking - 6.64
„, , . , , final wrifftv of sampla-initial wtigltt of tempi* . . „ __
% water socking by sample = -——-£ -—"■■■■-■- <■" - ■•». ••• x 100
° J r :nSfi'fli wiight of serr\pl*
% water socking by sample = 6,(A."fk*2 ^100
= 3.426 % No effect on dimension after 24 hrs. removing from water.
Sample 2 • Effect on weight-Initial weight of sample -10.38 Final weight of sample after water soaking - 10.70
~ ,-i , final weight of sample-initial weight of sample „ « __
% water socking by sample = ———— :—-—*——■ -——-— X 100
tnttial.wtight pf tamplt
% water socking by sample = " «'•■'■• xlOO
= 3.08285% No effect on dimension after 24 hrs. Removing from water.

TRIBOMETER TR - 20E Reading Calculation-Pin o disc reading taken at maximum 692 rpm READING 1-Pin on disc test
Force applied = 3 kg
Pin diameter =12 mm
Speed =692 rpm
Track diameter = 120mm

Time (minute) Friction force Wear rate Coefficient of friction
5 17.8 5 0.604825008
10 19.3 4 0.655793408
15 22.3 11 0.757730207
20 25.5 8 0.866462793
25 25.6 23 0.869860686
30 25.4 43 0.8630649
35 21.9 48 0.744138634
40 27.7 . 37 0.941216446
45 29.5 . 39 1.002378525
50 28,9 41 0.981991165
55 31.7 35 1.077132178
60 31.5 39 1,070336391
65 32.5 40 1,104315324
70 31.5 48 1.070336391
75 31.6 1 47 1.073734285
80 31.4 50 1.066938498
85 . 32,7 55 1.111111111
90 32.9 52 1.117906898
95 33 55 1.121304791
100 30.5 67 1.036357458

105 31.1 70 1.056744818
110 29 77 0.985389059
115 27.2 '79 0.924226979
120 27.4 76 0.931022766
125 28.1 87 0.954808019
READING 2 -
Pin diameter ~ 12 mm
Force applied = 2 kg
Speed = 692 rpm
Track diameter == 120mm

Time (minute) Friction force
(N) . Wear rate Coefficient of friction
5 6.9 13 0.3516
10 11.5 44 0.5861
15 12.5 69 0.6371
20 13.5 103 0.6880
25 14.4 140 0.7339
30 14.1 160 0.7543
35 14.2 164 0.7237
40 16.5 164 0.8409
45 16.5 162 0.8409
50 17.01 165 0.8669
55 18.01 165 0.9179
60 16.9 170. 0.8613
65 16.2 178 0.8256
70 16.0 180 0.8154
75 17.2 180 0.8766
80 16.0 187 0.8154

85 16.5 189 0.8409
90 16.5 197 0.8409
95 16.1 199 0.8205
100 16.9 200 0.613
105 17.6 205 0.8970
110 16.5 205 0.8409
115 16.9 216 0.613
120 17.0 216 0.8662
125 17.0 220 0.8661
READING 3-
Pin diameter = 12 mm
Force applied = 1 kg
Speed a 692 rpm
Track diameter == 120mm

Time (minute) Friction force (N) Wear rate Coefficient of friction
5 5 4.4 0.44852
10 3 3.5 0.356778
15 11 2.9 0.29561
20 13 3.9 0.39755
25 17 5.6 0.5708
30 14 7.8 0,7951
35 15 7,1 0.7237
40 19 6.7 0.6829
45 23 6.9 0.7033
50 20 6.7 0.6829
55 30 7.1 0.7237
60 32 6.7 0.6829

READING 4 -
Pin diameter= 12 ram
Force applied = 1 kg
Speed = 692 rpm
Track diameter- 120mm
Sample heated on mild steel plate on blue flame up to metal plate
get not get red.

Time (minute) Friction force (N) Wear rate Coefficient of friction
5 2.4 19 0.24464
10 7.0 21 0.71355
15 7.1 25 0.72375
20 7.0 25 0.71355
READING 6-
Pin diameter= 12 mm
Force applied = 1 kg
Speed = 692 rpm
Track diameter= 120mm
By Appling brake fluid on brake disc

Time (minute) Friction force (N) Wear rate Coefficient of friction
5 -0.9 -3 -0.09174319
10 -0.3. 0 -0.061162079
15 0 2 .0.07135575943
20 0 -2 -0.07135575943

READING 7 -

Pin diameter= Force applied = Speed= Track diameters

12 mm
2 kg
692 rpm
120mm

Pin at wet condition

Time (minute) Friction
force (N) Wear rate Coefficient of friction
5 11.1 0 0.565
10 13.8 3 0.7033
15 13.0 1 0.6625
20 13.3 6 0,677
25 12.5 13 0.637
30 13.8 15 0.7033
35 11.0. 21 0.560
40 10.5 19 0.5351
45 . 10.4 24 0.53
Wear rate calculations -
Diameter of pin = 13 mm
Height of pin = 25 mm
Density = 1.22 * 10"3 gm /mm3 = 1.22 * 104 gm /m3
Are®, A — nrS;
A= 132.73 mm2= 1.32723xl0*4m2
volume — A * h
= 132.73 * 25 = 3318.30724 mm3 = 3.31830724xl0-6m Test 1 = Wear = 87> μm=87xl0"6m

Wear material volume of pin = cross section of pin * wear in meter
= 1.32723x10^* 87x10"6 = U54690xl0'8m3 Total weight of wear material in two hrs. =. Density of wear material * Wear material volume of pin
= 12200000* U54690x10* = 0.14087218 mg Total weight of wear material in per minute = Total weight of wear materia} in two hrs. /120
=0.14087218/120 = 1.173934833 x 10-3mg/min Velocity of pin on pin on disc -
V = r. ω = 27tnr = 2TC*692*60
= 260877.854 m/min
r . Total weight of wear mawial in per minute
Total wear of pin = — ——-—-2-± S—. —
Velocity of pin on pin on osac
_ 1.173 934833 X 10^3
~ 260B77.9&4
= 4.499940548* 10'9gm/m Test 2 =
Wear = 220 um = 220xl0-6m
Wear material volume of pin = cross section of pin * wear in micron
= 1.32723xl0"4*220xl0*6
= 2.919906xl0"8m3
Total weight of wear material in two hrs. = Density of wear material * Wear material volume of
pin = 12200000*2.919906xl0"8
= 0.356228532 mg ' Total weight of wear material in per minute = Total weight of wear material in two hrs, /120
=0.356228532/120 =2.9685711 xl0;3mg/min
Velocity of pin on pin on disc -
V = r. ω = 2ᴫnr = 2ᴫ*692*60

Total wear of pin =

= 260877.854 m/min .
Total weigh; of w«»r■mwwM **> P4r mipuw Velocity of pinonpin on disc
2.96SS711X 10-3

260877,eS4 '
= 1.137916099*10-8gmym

Results obtain during test -
1. Sieve Size
2.- Porosity
3. Density
4. Thermal resistance (700 °C for 5

UU/k7 \J 100 to 500 micron
■ X0%
- *.3*103
• 23.65% Ash

hrs)
5. Compression test 54MPa
6, Shore D hardness 74
7. Shear strength 6Mpa
8. Water socking (by weight)
9. Pin on disc-
For testing sample cast iron disc are used.
Specification of specimen (pin):. 3%
Diameter of specimen 12mm
Length of Specimen 32mm

Parameters:
Track diameter . - 120mm
Speed - 695rpm
Load applied - 1 kg, 2 kg, 3 kg (9.81 N, 19.62N,
29.43N)

Sr. No. Condition
(dry/wet) Test time Load applied
(kg) Coefficient of friction Wear (micron)
1 Dry 125 min 3 kg 0.9 87
2 Dry 125 min 2 kg 0.7 210
3 Dry 60 min 1kg 0,6 6.7
4 Dry (heat treatment) 20 min Ikg 0.6 25
5 Wet (lubricant -Brake fluid) 20 min 1 kg 0 2
* Wet (lubricant "Brake fluid) 20 min " 2kg 0.15 5
'..7 ' Wet (Water) 20 min 2kg 0.6 24

CLAIMS
I claim
V"
1. In composite brake pad, bagasse is used as a reinforcing fiber and epoxy resin as a binder with different additives. Composition may vary as per required strength
2. As compare with other material, Bagasse has low wear rate and high coefficient of friction ( > μ = 0.6 to 0.9) at normal condition.
3. During the braking action, less noise is generated and occurs low brake fade of composite brake pad.
4. In water socking and oil socking testing, I observed, {hat composite brake pad having good resistance with water and oil due to epoxy resin and silicon powder.
5. Compression strength of brake pad material are obtained is optimum for light, weight vehicle, and good in shear as compare to other.