Design and Development of Brake Lining

Oct 13, 2025 by vinooalluri.com 12 views

Introduction

The development of non-asbestos brake lining using coconut fiber powder as the main ingredient has gained significant attention in recent years. Asbestos brake lining, which usually consists of 40% to 60% asbestos, 12% to 15% resin, and other materials such as used and copper tire rubber, has been widely used in the past. However, due to its hazardous health effects, the use of asbestos has been banned in many countries. As a result, researchers have been exploring alternative materials to replace asbestos in brake lining production. In this study, we focus on the development of non-asbestos brake lining using coconut fiber powder as the main ingredient.

Background of the Study

Brake lining is a crucial component in a motorcycle braking system, and its performance directly affects the safety of the rider. The traditional brake lining made from asbestos has been widely used due to its high friction coefficient and durability. However, the use of asbestos has been linked to various health problems, including lung cancer and mesothelioma. As a result, the use of asbestos has been banned in many countries, and researchers have been exploring alternative materials to replace asbestos in brake lining production.

Objectives of the Study

The main objective of this study is to develop non-asbestos brake lining using coconut fiber powder as the main ingredient. The specific objectives of this study are:

To design and develop non-asbestos brake lining using coconut fiber powder with composition variations.
To test the characteristics of the developed brake lining, including hardness, roughness, wear, braking distance, braking time, coefficient of friction, and heat increase due to friction.
To evaluate the performance of the developed brake lining in terms of braking distance, braking time, and coefficient of friction.

Methodology

The methodology used in this study involves the following steps:

Design and Development of Brake Lining: The brake lining was designed and developed using coconut fiber powder with composition variations. The three variations of the composition used are: 20% coconut fiber powder, 15% mgo, 15% Al, and 25% epoxy resin; 25% coconut fiber powder, 15% mgo, 10% Al, and 25% epoxy resin; and 30% coconut coir powder, 15% MGO, 5% Al, and 25% epoxy resin.
Testing of Brake Lining Characteristics: The characteristics of the developed brake lining were tested using a universal testing machine. The parameters tested include hardness, roughness, wear, braking distance, braking time, coefficient of friction, and heat increase due to friction.
Evaluation of Brake Lining Performance: The performance of the developed brake lining was evaluated in terms of braking distance, braking time, and coefficient of friction.

Results and Discussion

The results of this study show that the brake lining with a certain composition can achieve the value of hardness, roughness, and wear that approaches market products. For example, brake lining with composition A has a hardness value of 19.30 kgf/mm², roughness of 2.908 µm, and wear 0.0331 grams/mm².S.

In terms of performance, this brake lining also shows promising results. At a speed of 60 km/h with a brake pedal compressive force of 30 N, the tested brake lining composition provides a braking distance of around 15.2 m, a braking time of 2.04 seconds, and the coefficient of friction 0.6364. Although these values have not been fully comparable to the federal brand brake lining which has a braking distance of 17.28 m and a braking time of 1.94 seconds, this study shows the potential for the use of coconut fiber powder as an alternative raw material for non-asbestos brake lining.

Conclusion

This research shows that brake lining made from coconut coir powder has characteristics and performance that can be developed to compete with non-asbestos products that are already on the market. This innovation not only provides an environmentally friendly alternative, but can also use agricultural waste more efficiently. With further improvement in the production and testing process, brake lining based on coconut fiber can be a better choice in the future.

Recommendations

Based on the results of this study, the following recommendations are made:

Further improvement in the production and testing process is needed to improve the performance of coconut fiber brake lining.
The use of coconut fiber powder as an alternative raw material for non-asbestos brake lining should be explored further.
The development of coconut fiber brake lining should be scaled up to commercial production levels.

Limitations of the Study

This study has several limitations, including:

The study was conducted using a limited number of samples, which may not be representative of the entire population.
The study only tested the characteristics and performance of coconut fiber brake lining, and did not explore other potential applications of coconut fiber powder.
The study did not consider the economic and social implications of using coconut fiber powder as an alternative raw material for non-asbestos brake lining.

Future Research Directions

Future research directions include:

Scaling up the production of coconut fiber brake lining to commercial production levels.
Exploring other potential applications of coconut fiber powder, such as in the production of composite materials.
Conducting further research on the economic and social implications of using coconut fiber powder as an alternative raw material for non-asbestos brake lining.

Q: What is the main objective of this study?

A: The main objective of this study is to develop non-asbestos brake lining using coconut fiber powder as the main ingredient.

Q: What are the specific objectives of this study?

A: The specific objectives of this study are:

To design and develop non-asbestos brake lining using coconut fiber powder with composition variations.
To test the characteristics of the developed brake lining, including hardness, roughness, wear, braking distance, braking time, coefficient of friction, and heat increase due to friction.
To evaluate the performance of the developed brake lining in terms of braking distance, braking time, and coefficient of friction.

Q: What are the composition variations used in this study?

A: The three composition variations used in this study are:

20% coconut fiber powder, 15% mgo, 15% Al, and 25% epoxy resin.
25% coconut fiber powder, 15% mgo, 10% Al, and 25% epoxy resin.
30% coconut coir powder, 15% MGO, 5% Al, and 25% epoxy resin.

Q: What are the parameters tested in this study?

A: The parameters tested in this study include:

Hardness
Roughness
Wear
Braking distance
Braking time
Coefficient of friction
Heat increase due to friction

Q: What are the results of this study?

A: The results of this study show that the brake lining with a certain composition can achieve the value of hardness, roughness, and wear that approaches market products. For example, brake lining with composition A has a hardness value of 19.30 kgf/mm², roughness of 2.908 µm, and wear 0.0331 grams/mm².S.

Q: What are the implications of this study?

A: This study shows that brake lining made from coconut coir powder has characteristics and performance that can be developed to compete with non-asbestos products that are already on the market. This innovation not only provides an environmentally friendly alternative, but can also use agricultural waste more efficiently.

Q: What are the limitations of this study?

A: This study has several limitations, including:

The study was conducted using a limited number of samples, which may not be representative of the entire population.
The study only tested the characteristics and performance of coconut fiber brake lining, and did not explore other potential applications of coconut fiber powder.
The study did not consider the economic and social implications of using coconut fiber powder as an alternative raw material for non-asbestos brake lining.

Q: What are the future research directions?

A: Future research directions include:

Scaling up the production of coconut fiber brake lining to commercial production levels.
Exploring other potential applications of coconut fiber powder, such as in the production of composite materials.
Conducting further research on the economic and social implications of using coconut fiber powder as an alternative raw material for non-asbestos brake lining.

Q: What are the potential benefits of using coconut fiber powder as an alternative raw material for non-asbestos brake lining?

A: The potential benefits of using coconut fiber powder as an alternative raw material for non-asbestos brake lining include:

Environmental benefits: Coconut fiber powder is a biodegradable and renewable resource.
Economic benefits: Coconut fiber powder is a cost-effective alternative to traditional brake lining materials.
Social benefits: Coconut fiber powder can help to reduce the environmental impact of brake lining production and use.

Q: What are the potential challenges of using coconut fiber powder as an alternative raw material for non-asbestos brake lining?

A: The potential challenges of using coconut fiber powder as an alternative raw material for non-asbestos brake lining include:

Technical challenges: Coconut fiber powder may not have the same performance characteristics as traditional brake lining materials.
Economic challenges: The cost of coconut fiber powder may be higher than traditional brake lining materials.
Social challenges: The use of coconut fiber powder may require changes to existing manufacturing processes and supply chains.