THE BRAKE SYSTEM AND BRAKE SERVICE

1 Corinthians 9:25
And everyone who competes for the prize is temperate in all things. Now they do it to
obtain a perishable crown, but we for an imperishable crown.
2 Timothy 1:7
7 For the Spirit God gave us does not make us timid, but gives us power, love and self-
discipline.
Factors Governing Braking
 Four or five basic factors determine the braking power of a system.
 The first three factors govern the generation of friction: pressure, coefficient of friction,
and frictional contact surface. The fourth factor is a result of friction. It is heat or, more
precisely, heat dissipation and weight transfer .
 Brake fade is a condition where the stopping power of the brakes has been drastically
reduced. This is commonly caused by excessive heat buildup. With brake fade, the brake
pedal seems normal but there is reduced stopping ability. Brake fade may become worse
as heat builds up; this may be due to outgassing.
THE BRAKE SYSTEM AND BRAKE SERVICE
Brake Lining Friction Materials
 Brake linings are made up relatively soft but tough and heat-resistant material with a
high coefficient of friction.
 The lining is typically attached to a metal backing with rivets or high-temperature
adhesives. For many decades, asbestos was the standard brake lining material. It offers
good friction qualities, long wear, and low noise.
 But new materials are being used because of the health hazards of breathing asbestos
dust. Asbestos has not been used in brake linings or pads since 2003.
 Nonasbestos Organic Nonasbestos organic (NAO)
 linings are installed on many vehicles by the OEM.Organic linings are made of nonmetallic
fibers bonded together to form a composite material. Today’s organic brake linings
contain the following types of materials:
 ■ Friction materials and friction modifiers. Some
THE BRAKE SYSTEM AND BRAKE SERVICE
Brake Lining Friction Materials
 ■ Friction materials and friction modifiers. Somecommon examples of these are graphite,
powdered metals, and even nut shells.
 ■ Fillers. Fillers are secondary materials added for noise reduction, heat transfer, and
other purposes.
 ■ Binders. Binders are glues that hold the other materials together.
 ■ Curing agents. These accelerate the chemical reaction of the binders and other
materials. Organic linings have a high COF, and they are economical, quiet, wear slowly,
and are only mildly abrasive to drums. However, organic linings fade more quickly than
other materials and do not operate well at high temperatures. High-temperature organic
linings are available for high-performance use but they do not work as well at low
temperatures. They also wear faster than regular organic linings.
THE BRAKE SYSTEM AND BRAKE SERVICE
Brake Lining Friction Materials
 Metallic Linings Fully metallic materials were used for many years in racing. Metallic
lining is made of powdered metal that is formed into blocks by heat and pressure. These
materials provide excellent resistance to brake fade but require high brake pedal
pressure;they create the most wear on rotors and drums. Metallic linings work very poorly
until they are fullywarmed. Improved high-temperature organic linings and semimetallic
materials have made metallic linings almost obsolete for late-model automotive use.
Metallic linings are also extremely noisy,
 Semimetallic Linings Semimetallic materials are made of a mixture of organic or
synthetic fibers and certain metals molded together. Semimetallic linings are harder and
more fade resistant than organic materials but require higher brake pedal effort. Most
semimetallic linings contain about 50% iron and steel fibers. Copper also has been used in
some semimetallic linings and, in smaller amounts, in organic linings. Concerns about
copper contamination of the nation’s water systems has led to its reduced use in brake
linings, however. Semimetallic linings operate best above 200oF (93.3°C) and actually
must be warmed up to bring them into full efficiency. Consequently, they are typically
less efficient than organic linings at low temperatures.
THE BRAKE SYSTEM AND BRAKE SERVICE
Brake Lining Friction Materials
 Currently, semi-metallic linings are used only on the front disc brakes of passenger cars
and light trucks. The lighter braking loads on rear brakes, particularly on FWD cars, may
never heat semi metallic linings to their required operating efficiency. Semi metallic
linings also have a lower static COF than organic linings, which makes them less efficient
with parking brakes.
 Synthetic Linings The goals of improved braking performance and the disadvantages of
the other lining materials have led to the development of synthetic lining materials.
They are classified as synthetic because they are made of nonorganic, nonmetallic, and
non-asbestos materials. Two types of synthetic materials are commonly used as brake
linings for drum brakes: fiberglass and aramid fibers.
 Fiberglass was introduced as a brake lining material to help eliminate asbestos. Like
asbestos, it has good heat resistance, good COF, and excellent structural strength. The
disadvantages of fiberglass are its higher cost and its reduced friction at very high
temperatures. Overall, fiberglass linings perform similarly to organic linings and are used
primarily in rear drum brakes.
 THE BRAKE SYSTEM AND BRAKE SERVICE
 The equation of kinetic energy i.e energy of motion is given by

WHERE
)
)

But the work done in brake systems is given by

Where
THE BRAKE SYSTEM AND BRAKE SERVICE
 When braking a vehicle to stand still
And the average brake force
THE BRAKE SYSTEM AND BRAKE SERVICE
For example a car of mass 800kg is travelling at a speed of 36km/h. Determine
 (a). The kinetic energy it possesses
 (b). The average braking force to bring the vehicle to rest in a distance of 20m
Brake stopping distance and efficiency
 Braking means producing a force which opposes the motion of the vehicle wheels hence
reduction in speed and bringing the vehicle to a halt
 The force or resistance to stop a vehicle or reduce its speed is known as the braking
force.
 The braking efficiency of a vehicle thus is the braking force produced as a percentage of
the total weight of the vehicle as in the following equation shows.
THE BRAKE SYSTEM AND BRAKE SERVICE
 The braking efficiency is normally less than 100% due to insufficient road
adhesion and gradient or if the brakes have other issues.
 The brake efficiency is similar to the coefficient of friction as it is a ratio of the
frictional force to the normal load between the rubbing surfaces.

WHERE
THE BRAKE SYSTEM AND BRAKE SERVICE
 The determination of the brake stopping distance can be estimated using equation of
motion by assuming the brake efficiency is 100% effective. Using the following equation

 Where

 If the final speed of the vehicle is zero (), then .

 To convert km/h to m/s

THE BRAKE SYSTEM AND BRAKE SERVICE
Class exercise

 For example: Calculate the minimum stopping distance for a vehicle travelling at
60km/h
BRAKE SERVICE
 Brake service can be defined as the inspection and correction of
anomalies associated with brake wear and deterioration due to use or
age of a vehicle.
 Brakes and brake repair service for the entire braking system and
brake problems, such as brake pads, brake fluid, and rotors, are
important in helping ensure the safety of you and your passengers in
your car, truck or other automobile with brake issues.
 In order to begin inspection and repair or replacement of the brake
system, there are a number of signs that indicate your brakes need
attention or service.
BRAKE SERVICE
Repair & Replacement
 Brakes are designed to wear out.
 The pads rub on the brake disk to stop your car, so worn pads are the
first part to check if you are experiencing any braking problems.
 A full inspection though will show underlying problems, as well as
what can be repaired and what needs replaced.
 Brake pad replacement is the most common repair job for automotive
brake systems.
BRAKE SERVICE
 For example If your brakes are making a squealing sound or you hear grinding when your car comes
to a stop, these may be signs that you need brakes service immediately.
 Consult a certified technician for a brake inspection any time you notice any irregularities in your
car’s braking performance or when the following symptoms appear.
 The brake pedal seems to be spongy or presses farther to the floor than usual
 Your vehicle pulls to the right or left when you brake
 Unusual noises or vibrations occur during braking
 You have grinding, squeaking or squealing brakes
 Your steering wheel is shaking
 Your car is wobbling or pulsating when you drive at highway speeds
 It’s been over a year or 12,000 miles since the last time your brakes were inspected
 You’re near or past the number of miles your vehicle’s manufacturer recommends between brake fluid
exchanges
 The brake warning light on your dashboard comes on and stays on
 Your vehicle requires longer distances to stop than it used to
 The brake pedal responds slowly
 The brake pedal requires excess pressure
BRAKE SERVICE
What will my brake service include?
 Since brake pads are only one possible problem with a brake system, there
are other items to be included in a brake service. Depending on the results
of the braking system evaluation, your vehicle brake service may include:
 Brake pads replacement
 Brake rotors / drums resurfaced
 Brake fluid flush & replacement
 Brake caliper & rotor re-alignment
 Brake caliper replacement
 Brake hose replacement
 Brake master cylinder replacement