Brake shoe
https://www.mk-kashiyama.com/en/brake-tips/manufacturing-process
Importance of replacement for brake pad
Friction material of the brake pad is worn out with the use.
Under the condition that friction material is worn more than prescribed, it may cause of reduction of
braking because of rapid wear. Also, these may lead to a damage to brake disc or brake drum.
Regular inspections are necessary, but if you feel any changes such as ineffectiveness, it is
recommended to check the condition of the brakes and replace them as soon as possible.
Indication of Replacement for Brake pad
Amount of brake pad reduction varies greatly depending on how the driver uses the brakes and the
driving conditions. After driving 20,000 km, we recommend checking at a maintenance shop.
When the remaining thickness of the pad becomes less than is 5 mm, the temperature of the friction
material is easy to rise, and even with the same mileage, it decreases faster than when it is new.
Therefore, we recommend the replacement at the thickness of 5 mm. If it is less than 2 mm, it will be in
a very dangerous state. Early replacement is important.
Brake pad life
If the brake pad replacement is delayed
These situations will cause the replacement of brake disc or a caliper and will take extra cost. More
importantly, it is very dangerous.
Contact between backing plate and brake disc because friction materials were completely worn out.
Brake disc was also damaged.
Caliper where the thin pad is displaced from inside the bracket and scrapes against the brake disc to
damage the yoke.
Troubleshooting Casebook
We have created a collection of trouble cases for drum brakes and disc brakes, so please have a
look.
PDF download
Automotive Brake Troubleshooting(PDF)
Before Troubleshooting
Car brakes are a very important safety component. Please be careful when handling the related
parts and proceed with the work carefully.
When replacing the brake shoes, please note the following two points.
1. Make sure the brake shoes and drums are cold due to the risk of burns.
2. Do not drop the brake shoes on the floor or give a strong impact.
Please note the following two points when replacing the pad.
1. Make sure the pads and rotors are cold due to the risk of burns.
2. Do not drop the pad on the floor or give a strong impact.
We also recommend that you outsource the replacement and maintenance of brake parts to a
certified contractor.
Q&A
There is a noise from the brakes.
It can be reduced by maintenance.
Sound type:
1. Screeching sounds Braking at low speed or just before the car stops.
2. Groan sounds Startup automatic car or stop foot braking when starting downhill.
3. Rasping sounds Brake operation while running at 30-40km/h.
Solution: Grinding of the rotor surface or replacement of the rotor
Maintenance of the caliper
Applying noise-protection grease and use anti-noise shim
Add chamfering of friction material, or grinding down the side of inner and outer periphery
When I step on the brake, the brake pedal and steering wheel are vibrating.
Rotor confirmation required.
Cause of judder:
・Check for rust and scratches on the rotor surface
・Rotor contact, deformation, and uneven wear of the rotor
Grinding of the rotor surface or replacement of the rotor depending on its condition.
The brake suddenly stopped working while driving.
Fade may occur.
Do not panic. Park your car in a safe place, and wait until the brakes cool down. Starting the car
again slowly.
What is Fade? : Excessive temperature increase generates the plastic decomposition gas from the
friction material, and the gas membrane between the pads and rotor results in weakening the
braking effect.
Raw Materials
Backing Plate
1.Acceptance of raw materials to use used for friction materials
1.Acceptance of backing plate to bond friction material
2.Make friction material by blending dozens kind of raw materials
2.Cleaning the backing plate and applying glue to the plate
Brake Pad Manufacturing
1.Forming friction materials into a brake pad
2.Adhering of backing plate with friction material by heat and pressure
3.Grooving and chamfering on brake pad
4.Spraying the powder on brake pad, then cured under heat
5.Grinding the surface and printing the lot number, then checking the products carefully
6.Scorching the surface of the friction material
7.Installing the wear indicator to the brake pad
8.Packed in a box as a set
9.Spot-check on each lot number
Comparison of Brake pad squeal rate Noise dynamo test
Squeal rate (%)
Squeal frequency data from the squeal noise matrix test with a roller noise dynamo.
Test results without shims which can stop squealing and grease.
Comparison of brake pad effectiveness Dynamo efficacy test
Effectiveness (coefficient of friction)
Friction coefficient (@ 100km / h 0.6G) according to the dynamo efficacy test JASO C406.
Comparison of Brake pad wear intensity Dynamo wear test
Proportion when the life of our products for passenger car is 100
Converted from pad wear data by dynamo wear test JASO C427 (SAE J2707 MethodA ).
Proportion of expected life when our product is 100.
SUPPORT & CONTA CT
10.Shipping only ship the products that have passed the test
Brake Shoe - Manufacturing Plant,
Detailed Project Report, Profile,
Business Plan, Industry Trends,
Market Research, Survey,
Manufacturing Process, Machinery,
Raw Materials, Feasibility Study,
Investment Opportunities, Cost And
Revenue, Plant Economics
The automobile is unique-technological achievement, which make the distance
shorter. With this a far distance is covered in very short time. In developing India the
use of automobile vehicles is increasing tremendously. The first motor car which was
imported to India came in 1898 and now from that time upto the present time there
are so many manufacturers who are manufacturing various Automobile vehicles. Brake
shoe is used in the brake of an automobile. Automobile brakes require more attention
than any other system in the vehicle. Brake shoes are used in the brakes of
automobile vehicles. This provides the base to the lining. This is the part, which feeds
pressure and transmits the force to the lining by expansion. This is a very important
part of the braking system. Due to high friction, the vehicle stops. An understanding of
the requirement of braking systems of automobile vehicles requires knowledge of The
purpose of brakes, An appreciation of their contribution to safety, Recognition of the
factors controlling the stop, An understanding of braking action, An appreciation of
possible stopping distances. Few Indian Major Players are as under • A M C L
Machinery Ltd. • Arvind Engineering Works Ltd. • Automotive Axles Ltd. • Bosch
Chassis Systems India Ltd. • Brakes India Ltd. • Echlin India Ltd. • Goa Auto
Accessories Ltd. • Mando India Ltd. • T A L Precision Parts Ltd.
Plant capacity: Brake Shoe (Aluminium
Based):2000 NOs/Day •Brake Shoe (Mild Plant & machinery: Rs 49 Lakhs
Steel Based) : 2000 NOs/Day
Working capital: - T.C.I: Cost of Project: Rs 148 Lakhs
Return: 28.00% Break even: 65.00%
