Design Modification, Manufacture, and Performance Evaluation of an Automobile Brake Pad Test Rig

Abstract

This study focuses on the design, modification, and performance evaluation of a low-cost brake pad test rig developed to address the challenge of limited access to testing facilities in developing regions. The objective was to create a locally fabricated, cost-effective system capable of evaluating key braking parameters, such as wear rate, stopping efficiency, and temperature rise, under controlled conditions. The modified rig was constructed using readily available materials, including a 1.5 HP electric motor, a Toyota Starlet 5-speed gearbox, a flywheel to simulate vehicle inertia, and a hydraulic braking system. Two brake pad samples (semi-metallic and organic composite) were tested at various speeds (196.6–851.7 RPM) and loads (10–50 kg) to examine their wear performance and thermal behavior.Results indicated that increased speed and load significantly impacted wear, stopping time, and disc temperature. Sample 1 consistently showed lower wear, reduced temperature rise, and shorter stopping times, demonstrating better thermal stability and braking efficiency. The modified test rig effectively replicated real-world braking conditions, offering a reliable and affordable platform for brake pad testing in developing regions. The study underscores the potential of this test rig for enhancing braking system research, material development, and safety evaluations in resource-limited environments.