Effect of silica on the mechanical properties of palm kernel shell based automotive brake pad
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Jan 5, 2022
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Abstract
This research investigated the role of silica on palm kernel shell (PKS) as friction lining materials in automotive brake pad production. The friction materials were crushed, milled and sieved into four different particle sizes of 100, 150, 200 and 350 µm. The formulations weight percentages employed included Resin (20%), steel slag (15%) and carbon black (5%) while palm kernel shell and silica were varied for each particle size. Individual formulation was mixed for about 10 minutes until formation of homogeneous mixture. Homogeneous formulation A, B, C and D respectively, was compacted into mould and later sintered at 150 oC for 10 minutes in electric furnace and subsequently treated to enhance quality. Produced samples were characterized and evaluated for surface hardness (SH), compressive strength (CS), flame resistance (FR), oil absorption (OA), water absorption (WA) and wear rate (WR). The particles were also characterized using Scanning Electron Microscope. The results revealed that sample D had highest SH and CS values of 105.5 Brinell hardness number (BHN) and 115.2 N/mm2 respectively with decreasing values as particle size increases. FR decreased from samples A to D, and also decreased as particle size increased. Deductively, Sample B with the sieved grade of 100 µm was the best with SH as 99.14 BHN, CS as 105.6 N/mm2, WR as 4.15%, FR as 38.98%, and WA rate as 4.26 % and CF as 0.45 and OA rate as 0.381%. Conclusively, this research developed a high quality eco-friendly PKS particle composite for the production of brake pad.
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References
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[28] C.V. Ossia, A. Big-Alabo and E.O. Ekpruke, “Effect of particulate grain size on the physicomechanical properties of green automotive brake pads from waste coconut (cocos nucifera) shells.,” Advances in Manufacturing Science and Technology, vol. 44. pp. 135-144, 2020.
[29] Z.U. Elakhame, O.A. Alhassan and A.E. Samuel, “Development and production of brake pads from palm kernel shell composites,” International Journal of Scientific and Engineering Research, vol. 5, pp. 735-744, 2014.
[30] U.P. Anaidhuno, S. Ologe, F. Maduike, C. E. Mgbemena, “The development of vehicle brake pad using local materials-(palm kernel, coconut and cashew shells as base materials),” IOSR Journal of Engineering (IOSRJEN), vol. 7, pp. 61-67, 2017.
[31] M. Afolabi, O.K. Abubakre, S.A. Lawal and A. Raji, “Experimental investigation of palm kernel shell and cow bone reinforced polymer composites for brake pad production,” International Journal of Chemistry and Materials Research, vol. 3, pp. 27-40, 2015.
[32] R.L. Norton, “Machine Design: An Integrated Approach,” (2nd ed.). Singapore: Addison Wesley Longman, 2001.
[33] J. Abutu, S.A. Lawal, M.B. Ndaliman, R.A. Lafia Araga, O. Adedipe, and I.A. Choudhury, “Production and characterization of brake pad developed from coconut shell reinforcement material using central composite design,” SN Applied sciences, vol. 1, 2019. doi.org/10.1007/s42452-018-0084-x.
[2] I.M. Dagwa, “Development of automobile disk brake pad from local materials,” Unpublished Ph.D. Thesis, University of Benin, Benin City, Nigeria, 2005.
[3] P.J. Blau, “Compositions, functions, and testing of friction brake materials and their additives,” Oak Ridge National Laboratory, Springfield, Virginia, pp. 29, 2001.
[4] J.M.F. Paiva, and E. Frollini, “Sugarcane bagasse reinforced phenolic and lignophenolic composites,” Journal of Applied Polymer Science, vol. 83, pp. 880-888, 2002.
[5] V.S. Aigbodion, U. Akadike, S.B. Hassan, F. Asuke and J.O. Agunsoye, “Development of asbestos –free brake pad using bagasse,” Tribology in Industry, vol. 32, pp. 12-18, 2010.
[6] B. Dan-Asabe, P.B. Madakson and J. Manji, “Material selection and production of cold-worked brake pad,” World Journal of Engineering and Pure and Applied Science, vol. 2, pp. 92-97, 2012.
[7] V. Roubicek, H. Raclavska, D. Juchelkova and P. Filip, “Wear and environmental aspects of composite materials for automotive braking industry,” Wear, vol. 265, pp. 167-175, 2008.
[8] O.S. Olokode, S.O. Fakolujo, P.O. Aiyedun, Z.O. Jaji, F.T. Owoeye, and B.U. Anyanwu, “Experimental Study on the Morphology of Keratin Based Material for Asbestos Free Brake Pad,” Journal of Basic and Applied Sciences, vol. 8, pp. 302-308, 2012.
[9] A. Kurt and M. Boz, “Wear behavior of organic asbestos based and bronze based powder metal brake linings,” Materials and Design, vol. 26, pp. 717-721, 2005.
[10] A.O.A Ibhadode and I.M. Dagwa, “Development of asbestos-free friction lining material from palm kernel shell,” Journal of the Brazilian Society of Mechanical Science and Engineering, vol. 30, pp. 166-173, 2008.
[11] I.M. Dagwa, and A.O.A. Ibhadode, “Some physical and mechanical properties of palm kernel shell (pks),” Botswana Journal of Technology, vol. 17, 2008. doi.org/10.4314/bjt.v17i2.52206.
[12] O.A. Koya, A. Idowu and M.O. Faborode, “Some properties of palm kernel and shell relevant in nut cracking and product separation,” Journal of Agricultural Engineering and Technology, vol. 12, pp. 33-44, 2004.
[13] S. Mohanty and Y.P. Chugh, “Development of fly ash-based automotive brake lining,” Tribology International, vol. 40, pp. 1217-1224, 2007.
[14] W.B. Wannik, A.F. Ayob, S. Syahrullail, H.H. Masjuki, and M.F. Ahmad, “The effect of boron friction modifier on the performance of brake pads,” International Journal of Mechanical and Materials Engineering, vol. 7, pp. 31-35, 2012.
[15] M.Y. Choa, S.J. Kim, D. Kim and H. Jang, “Effects of ingredients on tribological characteristics of a brake lining: an experimental case study,” Wear, vol. 258, pp. 1682-1687, 2005.
[16] H.D. Meng and L. Liu, “Stability processing technology and application prospect of steel slag,” Steelmaking (in Chinese), vol. 25, pp. 74-78, 2000.
[17] Q. Ren, Y.J. Wang, S.L. Li, “Technologies of steel slag and comprehensive utilization of resources,” Iron Steel Research, vol. 40, pp. 54-57, 2012.
[18] C.S. Chen, X.H. Chen, L.S. Xu, Z. Yang and W.H. Li, “Modification of multi walled carbon nanotubes with fatty acid and their tribological properties as lubricant additives,” Carbon, vol. 43, pp. 1660-1666, 2005.
[19] J. Gao, S. Li, Y. Zhang, Y. Zhang, P. Chen and P. Shen, “Process of re-resourcing of converter slag,” Journal of Iron and Steel Research International, vol. 18, pp. 32-39, 2011.
[20] Z.U. Elakhame, O.A. Alhassan and A.E. Samuel, “Development and production of brake pads from palm kernel shell composites,” International Journal of Scientific and Engineering Research, vol. 5, pp. 735-744, 2014.
[21] S.S. Lawal, K.C. Bala and A.T. Alegbede, “Development and production of brake pad from sawdust composite,” Leonardo Journal of Sciences, vol. 30, pp. 47-56, 2017.
[22] U.D. Idris, V.S. Aigbodion, I.J. Abubakar and C.I. Nwoye, “Eco-friendly asbestos free brake-pad: using banana peels,” Journal of King Saud University - Engineering Sciences, vol. 27, pp. 185-192, 2015.
[23] D.S. Yawas, S.Y. Aku and S.G. Amaren, “Morphology and properties of periwinkle shell asbestos free brake pad,” Journal of King Saud University – Engineering Sciences, vol. 28, pp. 103-109, 2016.
[24] O.K. Chinedu, “Optimization of design parameter for coal ash and palm kernnel shell brake pad using taguchi experiment design method,” International Journal of Innovation and Sustainability, vol. 2, pp. 66–72, 2018.
[25] R.S. Fono-Tamo and O.A. Koya, “Influence of palm kernel shell particle size on fade and recovery behavior of non-asbestos organic friction materials,” Procedia Manufacturing, vol. 7, pp. 440-451, 2016.
[26] R. Soundararajan, S. Karthik, P.A. Varthanan, A.A. Devanand, M.V. Balaji, P.S. Nandha and S. Sivaramam, “Authomotive brake pad by using functianlly graded hybrid composites and their behavior,” International Journal of Mechanical Engineering and Technology, vol. 9, pp. 318-328, 2018.
[27] C.H. Achebe, J.L. Chukwuneke, F.A. Anene and C.M. Enulonu, “A retrofit for asbestos-based brake pad employing palm kernel fibre as the base filler material,” Journal of Materials: Design and Applications, vol. 233, pp. 1906-1913, 2019.
[28] C.V. Ossia, A. Big-Alabo and E.O. Ekpruke, “Effect of particulate grain size on the physicomechanical properties of green automotive brake pads from waste coconut (cocos nucifera) shells.,” Advances in Manufacturing Science and Technology, vol. 44. pp. 135-144, 2020.
[29] Z.U. Elakhame, O.A. Alhassan and A.E. Samuel, “Development and production of brake pads from palm kernel shell composites,” International Journal of Scientific and Engineering Research, vol. 5, pp. 735-744, 2014.
[30] U.P. Anaidhuno, S. Ologe, F. Maduike, C. E. Mgbemena, “The development of vehicle brake pad using local materials-(palm kernel, coconut and cashew shells as base materials),” IOSR Journal of Engineering (IOSRJEN), vol. 7, pp. 61-67, 2017.
[31] M. Afolabi, O.K. Abubakre, S.A. Lawal and A. Raji, “Experimental investigation of palm kernel shell and cow bone reinforced polymer composites for brake pad production,” International Journal of Chemistry and Materials Research, vol. 3, pp. 27-40, 2015.
[32] R.L. Norton, “Machine Design: An Integrated Approach,” (2nd ed.). Singapore: Addison Wesley Longman, 2001.
[33] J. Abutu, S.A. Lawal, M.B. Ndaliman, R.A. Lafia Araga, O. Adedipe, and I.A. Choudhury, “Production and characterization of brake pad developed from coconut shell reinforcement material using central composite design,” SN Applied sciences, vol. 1, 2019. doi.org/10.1007/s42452-018-0084-x.