Numerical simulation of the compositions, processing, materials, and properties of automotive brake pad production

Abstract

The performance, safety, and durability of automotive brake systems are critically influenced by the material composition and manufacturing processes of brake pads. This study presents a numerical simulation-based analysis of the composition, processing techniques, material selection, and resulting mechanical and thermal properties of automotive brake pads. The research focuses on three major classes of brake pad materials ceramic, semi-metallic, and non-asbestos organic (NAO) commonly used in modern vehicles. Using ANSYS Workbench 2023 R1, a finite element model was developed to simulate the thermal and structural behaviour of brake pads under realistic braking conditions. Material properties were obtained from the literature and validated through comparative analysis with existing experimental data. The simulations evaluated heat distribution, wear characteristics, and stress responses during braking cycles to assess performance and reliability. Results revealed notable differences in thermal conductivity, frictional behaviour, and structural integrity among the three material types. Ceramic brake pads exhibited superior thermal resistance, while semi-metallic pads demonstrated higher structural strength but increased wear rates. NAO pads provided a balanced performance in terms of noise reduction, dust generation, and cost-effectiveness. The study offers critical insights into the optimization of brake pad materials and manufacturing processes through numerical simulation. The findings contribute to advancing automotive safety, promoting sustainable material development, and enhancing performance-based brake design.