how to produce brake pads
Thanks Autotechlabs(https://www.youtube.com/@chrisfix) for the amazing videos, In order to make brake pads, we first start with oiled stainless steel. 10mm steel is stamped onto the lining of the brake liner, which is then analyzed to ensure it meets OEM specifications. Next, the brake liner pad goes into the press for mechanical fixation. Then the lining is galvanized and finally the brake pad friction material is added. Manufacturers can add the desired friction material, such as semi-metallic, organic or ceramic friction materials. Finally, the spacers are made and installed on the brake pads, and then sent to the test!
brake pads manufacturing process
how brake pads made
Here you will find out the brake pad production step by step, and also check our quality control including The details of each process.
Raw materials purchase & mixing
1. First of all, the brake pads raw materials needed to buy high-quality brake pads are used to make friction materials for brake pads
2. According to different formulations, the friction material is automatically measured and mixed evenly through the mixer, and the stirring rate must reach 99.8% or more; actually, ceramic brake pad friction materials, low metallic brake pad materials, semi-metallic friction materials with different materials composition
What are organic brake pads made of?
Organic brake pads, also known as non-asbestos organic (NAO) pads, are primarily composed of a mixture of natural and synthetic fibers, fillers, and binding resins. The key materials typically used in organic brake pads include:
Fibers: Organic brake pads utilize fibers like glass, rubber, Kevlar, or cellulose. These fibers provide the necessary structural integrity and help in absorbing and dissipating heat generated during braking. Kevlar, known for its strength and durability, is often favored in higher-end organic pads.
Binders: Phenolic resins are commonly used as binders to hold the fibers together. These resins harden under heat and pressure, ensuring the pad maintains its shape and cohesiveness during intense braking.
Fillers: Fillers such as powdered metals, abrasives, and other materials are added to enhance specific properties like friction, wear resistance, and noise reduction. These fillers are crucial in determining the performance characteristics of the brake pad.
Friction Modifiers: Materials like graphite and cashew nutshell powder are included as friction modifiers. They help to stabilize the coefficient of friction, ensuring consistent braking performance across different temperatures.
Organic brake pads are softer and quieter compared to other types like semi-metallic pads. They produce less dust and are gentler on brake rotors, making them a popular choice for everyday driving, particularly in passenger vehicles. However, they may wear out faster and are generally less effective in high-performance or heavy-duty applications.
Brake pad material properties
Brake pad material properties are crucial in determining the performance, durability, and suitability of brake pads for various applications. Key properties include:
Friction Coefficient: This measures the ability of the brake pad material to generate friction against the rotor. A stable friction coefficient ensures consistent braking performance across different temperatures and conditions. Organic pads typically have a lower friction coefficient, while semi-metallic and ceramic pads offer higher, more stable friction.
Thermal Conductivity: This property refers to the material’s ability to conduct and dissipate heat. High thermal conductivity prevents overheating and brake fade, which is essential for maintaining braking efficiency. Semi-metallic pads usually excel in this area, making them suitable for heavy-duty applications.
Wear Resistance: Wear resistance indicates how well the material withstands abrasion and prolongs the lifespan of the brake pads. Semi-metallic and ceramic materials are generally more wear-resistant, offering longer service life compared to organic pads.
Noise and Vibration Dampening: This property affects the noise level and comfort during braking. Organic pads are known for their superior noise dampening, providing a quieter operation than harder materials like semi-metallic pads.
Dust Generation: Low dust generation is desirable to keep wheels cleaner. Ceramic pads are known for producing less dust, whereas semi-metallic pads may generate more.
These properties collectively influence the effectiveness, comfort, and longevity of brake pads, making the choice of material critical for specific driving needs.
backing plate production & polishing
1. With 10mm steel plate through the stamping machine stamping into a rigid back shape,
Note: Now many factories choose to use steel plate with a thickness of 5mm~8mm, which does not meet international standards and seriously affects the quality of brake pads. The purpose of doing so is to low prices, and will not consider product quality
2. The molding of the rigid back, and then burr treatment and brightness treatment, basically by sandblasting treatment, and the back is coated with glue, increase friction, improve tensile strength
forming workshop & heat treatment
1. Hot pressing is to integrate the friction material with the rigid back through heating and pressure. This process is very critical. If the pressure is not uniform or the heat is not enough, it is likely to cause product quality problems such as materials blocking and cracks in the friction material block.
2. The purpose of heat treatment is to ensure that the brake pads can maintain a high-quality state at high temperatures, and at the same time, it can also insist on whether the brake pads can be put on the market in the future after the late serious quality problems.
brake pads slotted & Chamfered
1. We use the equipment to slot and chamfer the thermoformed brake pads.
2. Slots and chamfers on brake pads enhance braking by improving heat dissipation, debris removal, and noise reduction. Slots allow air to circulate, cooling the pad and preventing dust buildup that can cause uneven wear. Chamfers, with their angled edges, enable smoother engagement with the rotor, reducing squeals and ensuring even wear distribution. Together, these features help maintain consistent, quiet, and efficient braking performance, while also extending the lifespan of both the brake pads and rotors, making them vital for the durability and effectiveness of the braking system in various driving conditions.
The features of Brake pad slots and chamfers
Brake pad slots and chamfers are design features that serve specific purposes to enhance the performance and longevity of the brake pads. Here’s a brief explanation of their roles:
1. Slots
- Heat Dissipation: Slots help in dissipating heat by allowing air to flow through the pad, reducing the risk of overheating and brake fade.
- Debris Removal: Slots provide a pathway for dust, gas, and debris to escape, preventing them from accumulating between the pad and rotor, which can cause uneven wear or glazing.
- Noise Reduction: By breaking up the contact surface, slots can reduce noise and vibrations, leading to quieter braking.
2. Chamfers
- Noise Reduction: Chamfers are angled edges on the brake pad that help reduce noise by allowing the pad to engage the rotor more smoothly, minimizing the chances of high-pitched squeals during braking.
- Improved Contact: Chamfers help in gradually engaging the rotor, reducing the initial impact and improving the overall contact pattern between the pad and rotor.
- Wear Distribution: They prevent the edges of the brake pad from digging into the rotor, promoting even wear across the pad surface and extending the lifespan of both the pad and rotor.
Together, slots and chamfers enhance braking performance by improving heat management, reducing noise, and ensuring even wear, contributing to a smoother and more efficient braking experience.
Power coating & accessories installation(Indicator)
1. Automatic painting production line. Powder paint must be used so that the color will remain unchanged for a long time after baking at high temperatures
Note: The paint color is usually red, black, green, etc. Of course, you can customize it according to the PANTONE color card.
2. The device is used for indicator installation. Some accessories are accompanied with brake pads. This can be installed by the installation personnel when installing brake pads
Brake pad testing and quality assurance
1. Before the brake pads are packaged, we carry out batch testing on all orders to ensure that the products delivered to customers are in line with ECE R90 quality management regulations, responsible for customers and end customers, and minimize product complaints as much as possible
Shim printing & packing
1. Brake pads are generally printed by laser information, including logo, Emark Number, brake pad code, and delivery time, all will according to your requirements
2. Brake pads are packaged, and brake pads boxes and cartons are customized according to customers. If you have questions, you can communicate with our sales staff, and we will have a professional design team to solve any problems for you.
Brake pad in stock and delivery
1. After the product packaging is completed, a secondary inspection will be carried out, and after the completion of the inspection, the product will be uniformly put into the warehouse, and the packaging and shipping mark will be processed to facilitate timely shipment when transportation is required.
2. After the brake pads are in the warehouse, book the space and arrange the shipment according to the customer’s requirements. If you don’t know much about the process, you can see how to ship
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