Abstract

The braking System is one of the most Critical Safety elements in a vehicle as the
capacity to Stop or slow down the vehicle in a fraction of a second is the Key to
preventing accident. To slow down the motion of the vehicle or bring the vehicle
to a halt , frictional force is being applied to the rotating wheels of the vehicle.
Frictional elements with high coefficient of friction must be used in order to
achieve this purpose. A brake pad is a frictional element that has been designed
with a frictional surface to carryout this braking function on a vehicles rotating
wheels. The structure of the brake ,consist of noise reduction shim , backing plate
and the frictional material. The coefficient of friction of the of the frictional
material used on the pad is between 0.3 to 0.4 average at 0.35.
 Chapter 1
1.1 Background of Study
The brake pad is a component of disc brake, used in automotive and other
applications. It Composes of steel backing plates with frictional material bound to
the Surface that faces the disc brake rotors. Brake pads convert the kinetic
energy of a vehicle to the thermal energy through friction. Two brake pads are
contained in the brake with their friction surfaces facing the rotor. When the
brakes are hydraulically applied, the caliper clamps or squeezes the two brake
pads together onto the spinning rotor to slow and stop the vehicle. When a brake
pad heats due to contact with the rotor, it transfer small amount of its frictional
material into the disc, leaving a dull grey coating on it. The brake pad and disc
(both now having the friction material) then stick to each other , providing the
friction that stops the vehicle.
In disc brakes, there are usually two brake pads per disc rotor ,these are held in
place and actuated by a caliper affixed to the wheel hub or suspension upright.
Depending on the property of the material, the weight of the vehicle and the
speed it is driven at, disc wear rate may vary.
The brake pads must usually be replaced regularly (depending on pad material)
to prevent brake pad fade. Most brake pads are equipped with methods of
alerting the driver when this needs to be done . A common technique is
manufacturing a Small Central groove whose eventual disappearance by wear
indicates the end of a pads service life. Other methods include placing a thin strip
of soft metal in a groove, such that when exposed (due to wear) the brake squeal
audibly. A soft metal wear tab can also be embodied in the pad material that
closes an electric circuit when the brake pad wear thin, lighting a dashboard
warning light.
1.2 Statement of the Problem

Nowadays, most brake pads used on Toyota Hilux are paint coated and due to
the frequent movement of the brake pad in the caliper, the paint coat wears off
easily exposing the steel metal , which causes the metal to corrode easily there by
shortening the service life . As a result of the brake pad the need to design and
construct a galvanized brake pad to be used on the braking system of Toyota Hilux
, which is going to put a Sacrificial layer on the backing plate to prevent them
from corroding, hence the service life of the brake pad is prolonged.

1.3 Aim of the project

The aim of this project is to design and construct galvanized brake pads to be
used on Toyota Hilux.

1.4 Objectives of the project

1. To fabricate a brake pad that can be used on a Toyota Hilux brake to carry-
out braking functions
2. To fabricate a brake pad that will be durable and efficient for a long time in
use.
3. To fabricate a brake pad that can withstand the load of a Toyota Hilux
during it’s wide range of operations.
4. To reduce the rate of accident that occurs among Toyota Hilux due to brake
pad failure.
5. To fabricate a brake pad that is highly corrosion resistant.

1.5 Scope of the project

The scope of the project includes the Selection of the right materials, sizing,
fabrication design, construction, machining of the black plate and shim of the
brake pad. The brake pad can withstand up to 42000N load before failure, and a
Sacrificial surface is provided in the case of corrosion attack.
1.6 The significance of the project
The significance of the project is the reduction of accidents on our road, involving
Toyota Hilux’s, due to brake pad failure, it also make available a corrosion
resistant brake pad in the market, which prolongs the Service life of brake pads.

1.7 Limitation of the project

The major constraints of this project is the availability of Laboratories to carry out
material testing and equipment to aid in the fussioning of the frictional material
to this surface of the black plate, and also the cost of producing a galvanized
brake pad is higher compared to the cost of producing a painted brake pad (which
is common today).

Definition of Terms