Modeling and Development of Local Raw Materials for Automotive Brake Pad

Abstract: This study explores the feasibility of developing sustainable composite brake pads for automotive applications using locally available raw materials. A numerical modeling approach with ANSYS is employed to simulate the performance of a hybrid composite material composed of phenolic resin as the binder, graphite as the lubricant, coconut fiber as the reinforcement, aluminum oxide as the abrasive, and a combination of palm slag and sawdust as fillers. Five different formulations were developed using the rule of mixture, maintaining a composition of 40% filler, 20% binder, 20% reinforcement, 10% lubricant, and 10% abrasive. The simulation evaluates key performance characteristics, including frictional behaviour, wear resistance, hardness, and thermal conductivity under various braking conditions. Results indicate that the proposed composite exhibits promising properties, such as stable frictional performance, enhanced hardness, reduced wear rate, and improved thermal management. By utilizing locally sourced materials like coconut fiber, palm slag, and sawdust, this research highlights a cost-effective and environmentally friendly alternative to conventional brake pad materials. The findings contribute to sustainable manufacturing practices in the automotive sector while promoting the reduction of industrial waste.