Reporr T

MANUFACTURING OF DISC BRAKES PADS
A
Project Report
Submitted
In the partial fulfillment
For the award of degree of
Bechlor in Mechanical Engineering
Undertaken at
ROULUNDS BRAKING (INDIA) Pvt. Ltd.
Livaspur,po-Bahalgarh,Dist-Sonipat,Haryana
Submitted by:-
Md. Zahid Hussain
(15113929)
Under Supervision of
Internal Supervisor External Supervisor
Er. Dheeraj Dhiman Mr. Neeraj Sharma
(D.G.M Production )
Department of Mechanical Engineering

SWAMI VIVEKANAND GROUP OF INSTITUTES, BANUR, PUNJAB
May 2019
Swami Vivekananda Group Of Institutes, banur, Punjab 2

CONTENT
1.PREFACE
2.ACKNOWLEDGEMNT
3.COMPANY PROFILE
4.FLOW DIAGRAM
5.QUALITY CONTROL
I. IQC.
II. IN PROCESS
III. PRODUCT TESTING
IV. CALLIBRATION
V. DOCK AUDIT
I. IQC
a) FLOW OF INCOMING INSPECTION
b) FLOW CHART
c)INSTRUMENTS USED
d) MATERIAL IDENTIFICATION
e) INSPECTION
i. BACK PLATE
ii. ACCESSORIES
iii. PACKAGING
f) DOCUMENTS USED IN IQC
II. PROCESS
1.TSB

2.GLUING
3.D.T
4.CURING
5.PSB
6.POWDER COATING
7.GRINDIND
8.FINISHING
i. SHIM FITMENT
ii. PRINTING
iii. RIVETING
iv. PACKAGING
III. PRODUCT TESTING
a) Gogan Hardness
b) Porosity
c) Compressibility
d) Density
e) Shear testing
f) Degree of rusting
g) Degree of blasting T-Pull test
h) Krauss friction coefficient test
i) Roughness Tester.
j) Powder Coating.
IV. CALLIBRATION
a) VERNIER CALLIPER
b) MICROMETER
c)DEAD WEIGHT TESTER
d) dockaudit
PREFACE
Today is the world of competition. In every sphere of life there is
severecompetition and only those companies are running successfully who are

able to overcome their drawbacks as well as their weaknesses and they are
having a complete and immense knowledge of what their customers, employees
need and want, and how much satisfaction one provides to its customers,
employees. Prevention is better than cure is an old time textured saying.
The findings not only help in performance appraisal and to measure the
satisfaction level of employment but also give the warning signals to guard it
against any prospective threats from both within and outside. A market leader
would never like to loose its position and Roulunds Braking (India) Pvt. Ltd. is no
exception.
Today companies most urgently and critically rethink their business mission and
marketing strategies. The present report studies the management problems at
Roulunds Braking (India) Pvt. Ltd. It throws light on various problems related to
the satisfaction level of employees of different departments like production ,
planning and control etc.
This report is largely based on interview of executives in different departments,
which are in touch with these problems.
In addition to this secondary data is obtained from handbooks published by
Roulunds Braking (India) Pvt. Ltd. and its official site .
CERTIFICATE

This is certify Md Zahid Hussain presently study Satisfaction was undertaken in
Roulunds Braking (I) Pvt. Ltd., in order to know the Maintenance of Roulunds
Braking (INDIA) Pvt. ltd. Therefore the major sources of information in this study
were employees.
Mr. B.Rameshan Mr.Neeraj sharma

( Head of AfT) (production deptt.)
(Signature) (Signature)
ACNOWLEDGEMENT
The big task if under taking a work is not singly possible indeed
the project report could never have been accomplished but for
the wholesome, science of accommodation and purposive
guidance to the director of Roulunds Braking (India) Pvt.Ltd. ,
Livaspur (Sonepat) Mr. s k yogi for providing me the
opportunity to undergo inplant training at R.B.I Pvt.Ltd. I take
this opportunity to express sincere thanks to the management of
Roulunds Braking (India) Pvt. Ltd. for permitting me to observe
the whole setup of the factory.
I am deeply indebted to Mr. Neeraj sharma (D.G.M Production)

who supervised our training. He has been a constant inspiration
and has helped me a lot in providing skilled guidance , inspite of
his busy schedule.
I offer my special heart fully thanks to Mr.T.P.Singh

( Engineer Production ) deserves special mention for their
invaluable thought our training period.
My sincere thanks and regards to following persons to provide

me enough support and courage to make my training successful
and to enhace my technical skills about Automobile Product.
1. Mr. S K YOGI (MD)

2. Mr. Naveen Kumar Shrivastava(Sr. Mgr. Maint.)
3. Mr. Parmod Saxena(Asst. Manager)
4. Mr. T.P. Singh (Engineer)
I also thankful to roulunds braking staff providing the
information required during my training periodI am grateful to
SAMIA KHAN (HR) & Mr. H.D.Paliwal ( Personal Manager)
for his useful suggestion during my training.

Company profile
Roulunds Braking (India) Pvt. Ltd. is a company registered under the

companies Act, 1956 having its works at Livaspur, P.O. Bahalgarh,
District Sonepat, Haryana is the manufactured and Exports of
asbestos free Disc Brakes Pads under the technical support from
Roulunds Braking, Denmark
Roulunds Braking (India) Pvt. Ltd. is leading manufacturer of Disc Brakes

Pads in India. Roulunds Braking (India) is known for Global quality
Asbestos free passenger vehicles Disc brake pads. Roulunds Braking
(India) started its production recently in 1998 under name Hilton
Roulunds (India) later changed to Roulunds Braking (India) and have
state of the art manufacturing facility at Livaspur, Sonepat in state
of Haryana..
The company is continuously supplying its friction material to highly

competitive European Market / USA Market or we can say that
company is 100% export oriented unit. The company products are
well accepted in the global market because of its quality,
competitiveness and delivery commitment.
The company is a wholly owned subsidiary of MAT (Midwest-Air

Technologies), based at USA , MAT is Investment Company.

The company total manpower is 1200 and turnover is 220 crore / annum.
About the Roulunds Braking

Founded in 1736 in Denmark, ROULUNDS BRAKING started braking
activities in 1926 and finally became ROULUNDS BRAKING in 2003
after joining MAT Group.
ROULUNDS BRAKING product portfolio now includes flexible brake

linings, brake pads, brake shoes, brake discs and brake shoe kits, for
passenger car and light commercial. From the sister company MENETA
the have direct access to the newest product development in back
plates and anti noise shims, which benefits our products and
customers.
ROULUNDS BRAKING has manufacturing facilities in India, China,

France and Denmark, with over 2,500 employees worldwide, with
steady growth.

 Date of Registration 21st April 1997
 Commencement of Production 1998 – 99
 Take over by MAT Group 2003
 Capital Employed 4.96 Crores
 Total Land Area 23850 sq. m.
 Covered Area (Plant & Machinery) 17315 sq.m.
 Average Number of Employees 1000 per month
 Plant capacity 36 Lakhs Disc Brake

Pads per Month

MAJOR CUSTOMERS
 BOSCH
 GM
 DELPHI
 LAND ROVER
 TATA
 AFFINIA
 ACDELCO
 BAER
 KBX
 SUZUKI
 SAAB
 FORD
 PBR
 SBS EUROBRAKE
 VOLVO
 JAGUAR
 VALEO
 AVIA
 IK

Fig:of process flow digram

Quality Control
1. IQC ( Incoming Quality control )
2. Process
3. Product Testing
4. Calibration
5. Dock Audit
1. IQC ( Incoming Quality control )
Incoming Quality control is the most important department in any

company. In incoming inspection of incoming raw material is to be
done here.In RBI we inspect following materials :
1. Back Plates
2. Accessories:
- Shims
- Clips
- Wire indicaters

- Rivits
- Bolts
- Kit sets
-
3. Packaging Materials
- Wooden Pallet
- Corners board
- Set Box
- Master Box
- Top Bottom
- Labels
- Brown Paper
- Leaflets
- Foams
IQA ( Incoming Quality Assurance)
Purpose:
For any industry incoming is the safe point that assures
the movement of the right material towards production and
no line rejection during further activities .
The incoming quality assurance is responsible for the receipt
material at RBI Unit # 1, Unit # 2, Alliance Friction
Technology. We have two stations for inspection of the raw
material. One for the powder , mixes and other is backe
plates, Accessories and packing material.
The receipt QA department assures the following point.
1) Fitment of back plate in tool during pressing

2) Fitment of hardware used with the braking pads.
3) Good packaging.
4) To fulfill the product requirements of customer.
5) Supplier relationship and Vendor development for
running a new products.
All materials, Parts and service relevant to space activities must be

verified at incoming area before to enter in space store.All material
bought for space applications must enter in the manufacturing area by
means of incoming inspection.
Flow of Incoming Inspection:
1. Receive the material from store department in specified format

FSTR-02.
2. As per sampling plan IS:2500 General inspection level S1 (PART:
1) we check the material .
3. The inspectors inspects the material visually then
dimensionally.They also inspect and check the material on fitment
basis if required.
4. We maintain the inspection report and write the test result in
specified format and registers.
5. The non – conformity is shown before quality purchase and EDD
department.
6. If the material is ok : The material given to store department with
a green tag.
7. If the material is accepted under deviation we take deviation note
from purchase department clear the material with green tag.

8. If the material is hold for rework it is kept in quarantine area
with a yellow tag
9. If the material is rejected it is send back to the supplier with a
rejection notice along with a claim report.
For all material movement activities ERP SAP.

After the preliminary verification about the materials and parts will
be checked as per relevant applicable documentation(visual
inspection dimensional inspection etc.)
The result of verification or check will be recorded in the incoming
inspection report.
The incoming inspection report will be under quality management
with particular reference to numbering and recording.
INSTRUMENTS USED IN INSPECTION
1. Height Guage.
2. Vernier Calliper.
3. Micro Meter.
4. Moisture Tester.
5. Rockwell Hardness Tester.
6. Magnetic V-Block.
7. Surface Plate.
8. Torque Driver.
MATERIAL IDENTIFICATION NUMBER

1. BACK PLATE(01V--)
2. ACCESSORIES(01T--)
3. SHIMS(01S--)
4. KIT SETS(01TK--
5.PACKAGING ITEM(01U-)-
INSPECTION
BACK PLATES
We are receiving back plates as per Drawing.

Check points in back plate:
We check back plate by two ways,
1.VISUAL INSPECTION : In visual inspection we check,

a) Burr.
b) Dent.
c) Embossing.
d) Vendercode.
e)Identification number.

f) Rust.
g) Oil.
h) Bend.
2.DIMENSIONAL INSPECTION: In Dimensional

inspection we check with controlled drawing provided by Engineering
design and development department.
The critical dimension for back plate are………….

……………………………..……………………
1) A dimension (Total length of back plate).

2) Flatness.
3) Reference dimensions for pip and holes.
4) Centre distances.
Our inspectors make inspection report on specified format and

maintain register as mentioned in PFD of incoming QA.
Identified back plate received from certain vendor.
Flatness checking of back plate.
1)PURPOSE:
To determine critical back plate dimensions.
2)EQUIPMENTS:
i) Vernier Calliper
ii) Tripod
iii) Micro meter
iv)Puppy dial

v) Height gauge
vi) Surface Plate
3)PROCEDURE
a) Ensure calibration of measuring instruments before they are used.
b) Check the zero error of the instrument before use.
THICKNESS OF BACK PLATE
a. Thickness of the backplate is measured with a micrometer

b. Care should be taken while measuring the thickness that
reading is not taken at any embossed surface.
FLATENESS OF BACK PLATE
1. Place the back plate on the tripod.

2. Exert the pressure on the puppy dial and set the reading zero of
the puppy dial.
3. Move the probe of puppy dial on the backplate and note down
the deflection of the pointer of puppy dial
OVERALL LENGTH OF BACK PLATE (A-

DIMENSION)
1. Place the back plate b/w the vernier's jaws.

2. Check overall length without disturbing the back plate.
MEASUREMENT OF 'B' DIMENSION

1. Check 'B' dimension of back plate with inside jaws of vernier
caliper.
CENTRE TO CENTRE DISTANCE BETWEEN

HOLES OF BACK PLATE
1. For the measurement of centre distance, first measure minimum

distance between the holes and note down the reading.
2. Measure the maximum distance between the holes and add this
reading to the previous one
3. Get the half of the total value.
4. Obtained result is the CD of holes of back plate.
PIP HEIGHT
1. Place the back plate on magnetic V-block

2. Set the scriber of height gauge at the bottom of pip (surface of
back plate) and set the reading zero
3. Move the scriber up and take reading while scriber set at the top
of pip
4. Obtained reading is the height of pip.
VISUAL

Back plate surface should free from dent mark, scratch mark, pit mark,
deep line mark, flaw mark, rust & burr.
RECORDING:
Record the observation in inspection report format.
BACK PLATE ACCESSORIES
Fig:of backplates
Check points in back plate:
We are receiving accessories like,
1. Lotus clip.
2. Shims
3. Clips
4. Wire indicaters
5. Rivits
6. Bolts
7. Kit sets
8. Wear indicaters

The main checking aids in accessories are
1. Visual.
2. Dimensional.
3. Fitment
4. Fitment of clip on shims
5. Bolt torque test
6. Force test for lotus clip
7. Connectivity of wire indicators
CLIPS
Fig:of backplates clips

(1) PURPOSE: To determine critical dimensions of accessory
(Clip).
(2)EQUIPMENTS: Vernier Caliper
(3)PROCEDURE:
a) Ensure calibration of measuring instruments before they are
used.
b) Check the zero error of the instrument before use.

c) Clean accessory and the instrument used with cotton cloth.
LENGTH AND WIDTH OF SLOT OF CLIP
a) Take the measure accessory i.e. clip and the length of slot
with inside Jaws of vernier caliper.
b) Turn the clip and measure the width of slot with same
method.
SHEET THICKNESS OF CLIP
Take the clip & measure the sheet thickness of clip at the flat area
i.e. measuring area
SHIMS
Fig:of backplate with shim

1)PURPOSE:
(a)To determine critical accessory dimensions (Shim).
2)EQUIPMENTS:
(a) Vernier Calliper
(b) Micro meter
(c) Surface Plate
3)PROCEDURE:
a) Ensure calibration of measuring instruments
before they
are used.
b) Check the zero error of the instrument before
use.
c) Clean accessory and the instrument used with
cotton cloth.
4)THICKNESS OF SHIM
(a) Thickness of the shim is measured with a

micrometer
(b) Care should be taken while measuring the thickness
that reading is not taken at any tappered or bend
surface.
5)OVERALL LENGTH OF SHIM (A-
DIMENSION)
a) Place the back plate b/w the vernier's jaws.

b) Check overall length without disturbing the back
plate.
6)CENTRE TO CENTRE DISTANCE BETWEEN

HOLES OF SHIM
(b) For the measurement of centre distance, first

measure
minimum distance between the holes and note
down the reading
(b)Measure the maximum distance between the holes
and add this reading to the previous one
(c)Get the half of the total value.
(d)Obtained result is the CD of holes of shim.
6)VISUAL
(a)All the shim should free from burr,dent and line

mark.
Packaging Materials
In packaging item we are receiving…………
1. Wooden Pallet
2. Corners board
3. Set Box
4. Master Box
5. Top Bottom
6. Labels
7. Brown Paper
8. Leaflets
9. Foams

Check points in packaging items:
1) Visual
a) Art work.
b) Crack
c) Spots
2) Dimensional
3) Moisture
Check point in Labels :

In labels we check…….
a) Art work.
b) Bar code(we check bar code with the help of Bar code reader)
PURPOSE
The purpose of this procedure is to define the method of
inspection of all bought out packaging material.
SCOPE
This is applicable to the following packaging materials

a. Wooden box
b. Wooden pallet
c. Corrugated pallet corner and accessories
d. Set box
e. Master box
f. Sticker (Label)

PROCEDURE
a. Receive inward information about the material to be inspected for
the day from packaging store.
b. Sampling plan - Take '05 Nos' sample randomly from the lot.
c. Inspection by Q.A. Inspector as per Sampling plan / Drawings.
d. Recording of the information about the lot in inspection report
specified format.
e. Paste one label as a sample on "Register-label inspection" with
signature of inspector and identification information.
f. If lot is rejected then put "Rejection Card" with lot and Raise Claim
Report through purchase deptt.
g. If rejected lot to be segregated then follow "Work Instruction for
Segregation/Rework"
RECORDING
a. Inspection report - Format
b. Register - Label Inspection
HARDNESS TESTING
(ROCKWELL HARDNESS TESTER)

Fig: goagan hardness testing machine.
PURPOSE:
To determine the Rockwell Hardness of Back plates and
accessories.
EQUIPMENT
Rockwell hardness tester.
CALIBRATION:
By using the standard blocks of known value, check two points on
std. blocks
for hardness, which should be same as the value of std. block.
PROCEDURE:

a) Select 'the indentor and load' and reset as per the required
scale.
b) Place the object (Back plate, b/p accessories etc) on the
specified plateform.
c) Rotate the plateform handle in the clockwise direction and
ensure that the both the needles in dial indicator coinside
with their respective set position.
d) Move the handle away from for applying set load on the
obeject and wait for the positioning of the needle at the dial
indicator.
e) Move the handle to the initial position for releasing the load
and wait for further positioning of the needle.
f) At the final position of needle, reading at the black scale/red
scale will be the hardness of the object.
Documents used in IQC:
1. Inspection Report
2. Material Inward
3. Claim Report
4. Deviation Report
5. Supplier Inspection
1. TSB

( Tumble Shot Blasting )
Purpose:
To make the uneven surface on the back plate specially on friction

side to increase adhesive between back plate and friction material
and also to improve the tensile strength, oilness and burr.
Process requirement;
 Time duration 20-25 min.

 Quantity of back plates.
 Steel shots size

Work Instruction:
1. Put the back plate in TSB machine as per specifications.

2. Close the TSB door correctly.
3. Set the Cycle time as per specifications.
4. Switch on the TSB m/c.
5. After TSB compare the parts B/P with Master samples.
6. After TSB check the roughness.
Critical points :
1. Clean the net of shot blaster after every cycle.

Product requirement :
 Roughness:- 20-40 micron.

 It should be homogenous / even throughout friction
area.
 If roughness is high that it will effect the product.
 If roughness is less.
 It affects the physical proper. Particularly shear
strength it decrease.
 Material : Blasting material is of two type
a. Grit 40
b. Steel shots
Cycle time :
Time duration for one cycle is 25 min.

Specification : 25 – 40 micron.
2.GLUING:
Purpose: It acts as a
adhesive between back plate
and friction
material
Requirement:
 Ethanol
 1099 sudan black
 Resin
Glue preparatiuon:
1. Take ethanol Sudan Black and Phenolic resin and mix well
and store in machine. It takes approx. 30 min. to prepare
glue.
2. Check the Glue viscosity ( 21 – 25 see with ford cup )
Process requirement;:
 Glue should be used after 24 hrs.
 Glue should be applied with rollers.
 Proper mixing of glue should be done.
 Proper drying temperature of glue.
 Idle glue container should be kept in A.C. room.
Viscosity :
 It is measured with the help of Ford Cup.
 20 -25 sec.

Manual Application of gluing – Unit 1 & 2 :
Glue viscosity : 21 – 25 sec. with FORD CUP.

Glue Weight : 0.10 – 0.40 gm / Back plate
Drying Temp. : 60 – 80  C
Glue Application Through Automatic Gluing M/C –
Unit 2 :
Glue viscosity : 50 - 60 sec. with FORD CUP.

Glue Weight : 0.10 – 0.40 gm / Back plate
Drying Temp. : 60 – 80  C
 Glue should be evenly spread on the surface.

 Glue should be properly dried.
Specification :
 0.2 – 0.5 gm.
NOTE :
- Glue should be used with in 7 days from the date of
prearation.
- Back plates should be free from rust  spots and oil etc. before
gluing.

3. D. T. Press
(Denmark / Dennis Technology )
Purpose:
 Main function of pressing is to attach the friction material
with the back plate.
 Making shape / dim. of friction material acc. to drawing
Material : Two types of material used to make pads.
 Friction material
 Under layer.
Process requirement;:
 Temp; Upto 150  C.
 Presure – depends upon pad area / ramped area.

 Time of cycle - 5 to 8 min.
 Moisture of mixture.
 Density
 Bulk Volume.
 Physical testing properties.
 Hardness.
 Density
 Shear strength
 Dim. wise
 Aceton Extraction.
Component : -
 4 Cylinders having capacity
 50 tonnes
 80 tonnes
 Works on Hydraulic principle
 Max. Pressure is 200
Hydraulics Sytem contain :
 2 moters ( 1. High pressure , 2. Low pressure )

 Pump
 Filter
 Incomperessible oil
 Heat Exchanger
 Accumulater
Tool :
- Punch
- Top plates

- Bottom plate
- Moulding dye ( material of dye is H-11 )
- Bumping Tool ( material is mild steel)
- Lifting Handle ( works on neumatic pressure )
Machine Specifications : -
( For DT ( Dennis / Denmark Technology )
Machine Make : HIND

Capacity : 50 Ton x 4
Electric Load : 26 KW
Hydraulic Oil : VG 36
Power Pack Capacity : 1600 Liters
Machine : 15 Ton
Tool Running on DT Press :

- Station no.
- Tool no.
- Mix no.
- Undert layer
- Back plate no.
- Friction Material wt.
- Under layer Wt.
- Pressing Thichness
- Set Temp. Top Mould ( 165 ± 5 C)
- Set Temp. Bottom Mould ( 160 ± 5  C)
- Gogan Hardness ( Gn ) ( 35 – 70 )
Line Pressure: It is set as per the pad area and no. of cavity ( 1 or 2).

Pressing Thicness (in mm) = Max. Finishing Thickness (imm)+0.5
Temperature and Pressure settings can be Fine Tuned to meet the

required product physical properties
Cycle time :
 Time of cycle – 5 to 8 min. for each cylinder
4. CURING
Curing is a process of baking the pad ‘ s friction material ( mix ) , to

attain the desired specific properties as per requirements.
Curing of Brake Pads is done in two ways as mentioned below:

1. Convyor Oven Curing. ( Traditional Method )
2. Batch Oven Curing . ( New Invented for Economic pupose
to increase production )
- Density
- Porosity
- Gogan Hardness
1. Convyor Oven Curing :
 Diesel Operated
 Electric Operated
Convyor Oven Specification :
Machine Type : Conveyor Oven

Temperature : 250± 20  C
Cycle Time : 2 hrs. ± 5 min. (can vary as per mix spec. )
Heating Zones : 6 in Diesel Oven , 3 in Electric Oven .
Conveyor Speed : 6.57 rpm.
Process Requirement
1. Cycle Time. ( 2 hrs. ± 5 min.)

2. Temperatures (250± 20  C )
Process :
1. Start the Heating Zones first .

2. Set the temperature of all Heating Zone with the help of
temperature controller.
3. Set the frequency as per specifications.
4. Place the pads in the tray and place the tray on conveyor.
5. Collect the pads after curing.
Critical Points :
1.Keep the pads in Kanban Trolley after curing , not in
pallet or wooden box
3. Batch Oven Curing :
Batch Oven Specification :

Machine Type : Batch oven
Temperature : 215 ± 5  C.
Cycle Time : Can vary as per mix spec.
Process :
 Fill the Material in the Bins & put on the oven troll

 Insert the trolly in the oven\
 Close the door of oven
 Select the Curing Cycle& Check the settings of receipe
 After Completion Open the door & pick Out the Material For Cooling
Instruction:
 Don’t Make Over Filling.
 No Burning Material Like Paper piece & cloth should be in trolly
 Make proper Closing
 Make sure that selected cycle is as per the requirment of material
5. PSB
(Pad Shot Blasting)
Purpose :

It is done for the prevention of rust and good visual appearance of the
pads.
Process Requirement :
In this process the powder is sprayed with the help of

powder gun on the pad for limited or fixed velocity and for a certai
Pad Shot Blasting :
Machine Type : Pad Shot Blasting

Conveyor speed : 120 ± 20 Hz
Shots Type : Grit ( Grey cast iron )
Back Plate Roughness : 25 – 40 Hz.
6. POWDERCOATING
Powder coating is done after the pad shout blasting .In this process, the
powder is sprayed with the help of powder gun on the pad for a limited
or fixed velocity and for a certain cycle time (different for different
pads).
After spraying powder it is send to the oven, where the temp. is fixed
acc. to the temp. specification.
Cycle time of oven is also fixedThe thickness of powder coating is fixed
acc. to the M/C i.e. Spraying gun.
Purpose:
It is done for the prevention of rust and for good visual
appearance of the pad.

- Paint Thickness
- Powder Source
- Air
- Impressed Voltage
- Fluidized Bed
- Pressure
- Powder Velocity
- Temperature
- Visual Appearance.
Specification : 20 – 50 micron.
7.GRINDING
Pupose:
- Grinding is a process of removing excess friction material to
maintain thickness of pad and parallism between back plate and
friction material.

- Grinding is done on the surface of the pads and lining. It is done
for after the Powder coating.
- Grinding is used for the grinding of PV pads and Multi spindle
Grinding is for CV lining.
- A limited thickness is grind very carefully with the help of
grinding m/c. i.e. grinding.
- This m/c is handled both manually & automatically by PLC m/c
in both the ways
1.Internal Grinding :
- Internal Grinding is done only for CV lining . Since
the lining has curved shape, therefore its needs both
internal and external grind to the lining.
2.. Extertnal Grinding :
It is also done for CV lining . In which outer curved
Portion is grind with the help of grinding M/C more
grinding may be reason of rejection of product.
MACHINE SPECIFICATION:-
Type : Pad Grinding m/c No. of m/c in RBI : 4
8. FINISHING
1. Shim Pasting
2. Printing

3. Riveting
4. Packaging
1. Shim Pastin
Purpose:
It is a anti noise in nature, hence it reduces the sound
produce by the brake on braking action.
 Shim is noting but a type of accessory only.

 It is made up of steel and the pasting material covers its one
side.
 It is done after grinding process.
 It is paste on the opposite side of the PV pads over the back
plate
 It is done manually.
Process:
 Pick brake pad from one piece station
 Remove the sticker from the shim
 Fix the shim on the pad in proper fitment

 Keep brake pad on fixture
 After fixing the pad press foot switch
 Pick pad from fixture and keep on one piece station

Instruction:
 Make proper fixing
 Don't Touch pasting Surface of Shim
 Hold the piece from Edges and Don't put one
piece over other
4. PRINTING
Purpose:
 Printing covers the company name , product code , batch no.
company code, etc. on it.
 It is a process in which the printing M/C is set manually and
the printing is done on the back plates of the pads.
 Printing is done with the help of ink , white in colour , on the
back plate side of the PV pads , CV pads.
 Lots of care is needed when the printing work is in progress.

 A little mistake can print the character inclindly or overprint
the characters, which results the rejection or rework for the
process.
Process
 Move Doctor blade to extreme position to take out cliché plate

 Take out printing pad from printing m/c
 Take out cliché plate from paint bath
 Clean Cliché Plate With Thinner
 Keep cliché plate in paint bath
 Set Printing Pad
 Set fixture for Positioning Brake pad
 Check printing on pad for first part approval
 Keep brake pad on fixture
 After fixing the pad press foot switch
 Wait to print
 After Printing Remove the printed piece by holding from
corners
Instruction:
 Make proper fixing
 Don't insert hand on the piece while pressing the switch
 Avoid hand movement near the fixture at the time Printing
 Don't put hand on the Printed Area
3. RIVETING
Purpose:

It is for the fitment of Accessories on the pads.
It is done after the printing work.
In this process riveting M/C is used for riveting.

Accessories should be rivited or not depend on
the customer.
Process:
 Put the fixture on the bed of machine

 Tight the fixture in the bolts
 Put the riveting Punch in the Rotary Spindle of M/c
 Set the Timer
 Adjust the Stroke Length of Spindle
 Keep brake pad on riveting fixture & Put the Clip on the Pad
 Press the pedal & keep clip tight by thumb
 Wait to Complete Riveting
 Remove pad from fixture and Pass to Next
4. PACKAGING
Purpose:
Pakaging is a process which is done after the finish all
manufacturing process and after final inspection of the product
packing process is start. According to requirement of customer
packaging is done .
Instruction : 1. first of all we should check set box ; master box; lable ;
leaflet ; sticker; pallet and wooden box before starting packing

We must fill first part approved before packing
Again after completion ; packing last part approval must be fill.
Process :
 Make a box by folding box
 Put the pad in the box.
 Give corrugating packing after one layer.
 Close the box with brown tape and paste the sticker
on the box.
 Put the box in polybag and shrink wrap.
 Put the box into pallet offer the palet for Dock
Audit with document
 Paste sticker approved for dispatch on the box after
Dock Audit
PRODUCT TESTING
Product testing is also an important parameter in which we check the

product after complition.
There are many types of checks like :
1. Gogan Hardness
2. Porosity
3. Compressibility
4. Density

5. Shear testing
6. Degree of rusting
7. Degree of blasting T-Pull test
8. Krauss friction coefficient test
9. Roughness Tester.
10. Powder Coating.
1. Gogan Hardness :
Purpose:

To determine the gogan hardness of the friction material.
Equipment Used :
1. Gogan hardness M/C ( Model 911 2V)
2. Standard Guage Block ( 12.7 mm thick)
3. Piston Dia 19.0 mm ( flat surface diameter )
4. Gogan Standard Set for caliberation
5. Fixture and Plate
Process:
 Pad should be placed flat on the machine spindle.
 Set the gap between piston and pad 12.7 with the help of
standard guage block
 Check the gauge pressure ( 1500 kgf ) while running the
test.
 No measurement should be repeated at the same spot.
Effects:
Less:
If Gogan reading is less then requ. Spec that means Pad is
hard ;
So when the brake is applied it will produce noise and there
are chances that Pad develops crack.
More:
If Gogan reading is more then requ. Spec that means Pad is
soft ;
In this condition the Pad will rub more and it would reduce
the life period of the pad.
2. Porosity :
Purpose : To determine the porosity of the given sample.
“ The percentage of volume of absorbed oil
relative to volume of the test piece is called Porosity”
Equipment Used :
1.Weighing Balance
2. Container
3. Thermostatic
4. Apparatus
5. Test Oil
6. Desicators
Condition : Conducted at room temp. of 23 ± 2 C

Related humidity 50 ± 5 %
Calculation:
Test is conducted and following data is recorded :

Mo = mass of the sample in air
M1 = mass of the sample in immersed liquid.
M2 = mass of the sample in immersed liquid after boiling
Porosity % = (M2 – M1) X 100
Mo – M1
3. Density :
Pupose :
To determine the density of given sample.
Condition : Conducted at room temp. of 23 ± 2 C

Related humidity 50 ± 5 %
Equipment Used :
1. Weighing Balance
2. Fixing support
3. Water Bath
4. Desicators
Calculation:
Test is conducted and following data is recorded :
Mo = mass of the sample in air
M1 = mass of the sample in immersed liquid.
Density ( g/cc) d = Mo / Mo – M1
4. Compressibility:

Pupose :
To determine the % reduced on the thickness of the brake

lining due to the compression force at ambient temp. & 400  C temp.
given in this statement.
Equipment Used :
1. Compressibility
2. Piston adopter ( same dia. As original piston )
3. New disc pad foir every test.
Compresbiluity of the pads depend upon mixing . It should became

according to the drawing

5. Shear Testing :
Purpose:
To determine the shear strength of the prepared disc.
- After Cross friction test
- Before Cross friction test
Effects:
If shear force is less then there are chances of breaking

Pad
Therefore larger the shear strength larger is the Pad strength
to avoid breaking.
Shear = Force ( KN) X 1000

Area (cm2)
= N /cm2
Minimum: 400 N /cm2

Equipment Used :
1. Universal Testing M/C.

2. Shear stress testing M/C with fixture numeric spot.
5. Salt spraying :

Purpose:
1. To determiner the resistance of curved paint towards
neutral saltr spray.
2. to find cross cut adhesive of paint of the coated surface.
Equipment Used :
1. ERICHEN muilty cross cutter

2. Spraying chamber type – “ PRESTOMAKE”
3. Scriber + ruler
4. NaCl Technical plinch ( butter salt ) 5 % soln. with
dissolved water
5. Technical balance
6.T – Pull Testing :

Fig:of t-pull tester
Purpose:
To determination of bonding strength of glued shim on
brake disc brake.
Equipment Used :
1. Bending equipment for shim 908

2. Tensile tester with hook and tensile clamp
Drilling equipment used :
1. Bending equipment for shim 908
2. Tensile tester with hook and tensile clamp
3. Drill
4. Slide guage
Method :
- Bend the shim to 908 and compared to the pad back plate.
- The radius of curvature must be approx. 0.5 mm so that

radius of bend of shim is 1 – 1.5 mm.
- Placed the pad over the fixture and tightened it.
- Placed the pad over the fixture and tightened it operate the
testing M/C as follow sand note down their reading.
8. Krauss friction Coefficient test :
Fig: of krauss friction tester

Purpose:
To check the performance of the friction pads.
Equipment Used :
1. Kruass Friction Tester - Volvo pads 2- no inner outer on
each LH side only with anti noise shim.
2. Volvo P-28 LH brake caliper & disc

3. Instrument (Micrometer ; tools etc.
Vehical Parameters that are considered :
1. Torque
2. Radius of the Wheel
3. Wheight of the Vehical
4. Capiler piston pressure
5. Speed of Vehicle
6. Inertia force of Vehicle.
Testing conditions:
1. Temperature: High, Low,Moderate.
2. Pressure : High, Low
3. Speed : Low, High
4. Torque: Constant
9. ROUGHNESS TEST :
Purpose:
To check the roughness of the back plate
Instrument used :
Surface Roughness tester.
Parameters
Ra ; Ry ; Rz ( having usual reference value in m )
Effects :
If roughness is:
Less : Raw material will not stick to the B/P.
More: If it is with in the tolerance greater then spec. upto 5 -6
micron. Then it is alright . but if it is greater then 20 -25
micro. Then it will lead to more utilization of the glue.

Result :
Roughness must be with in the specification.
10. Powder Coating :
Purpose:
To determine the level of powder coating on the Pad.
Instrument used :
Elcometer(Powder coating tester)
Effects :
On the application of the brack the heat is generated the

temp. of Caliper Disc rises.
Less :
If powder coating is less then due to heating the paint might
come out in the form of clips and this could lead to rusting of
the Pad in the future.

Result :
Powder Coating must be according to the specification
DEFECTS PRODUCED DURING
MANUFACTURING PROCESS
LIST OF DEFECTS
DEFECTS IN BACK PLATE

a) Dent
b) Operation miss
c) Rusty / corrosion
d) Burr observed
e) Rust problem
f) Pip shifted
DEFECTS IN PADS

a) Thicknes more
b) Crack
c) Gogan ; Denity ; Porosity ;Low / High.
d) Friction Burr
e) Groove Land Not ok
f) Chamfer not ok
g) Spot
h) Powder coating not ok
i) Shim pasting not ok
j) Printing not visible
k) Clip fitment not ok
l) Loose accessories
DEFECTS IN SHIMS:
a) Line mark
b) Laser cut
c) Burr Mark
d) Bubbles
e) Dust Particles
f) Pasting
g) Bend
h) Colour Variation
DEFECTS IN PAKAGING :
a) White Spot
b) Crack
c) Moisture
d) Art Work

e) Pasting
f) Colour Variation
DEFECTS IN CLIPS :
a) Plating
b) Bending
c) Rust
d) Dust
e) Burr
WEIGHING AND MIXING

SECTION
Preparation of mix ( Under Layer and Frition Material ) is done on

regular basis as per requirement.
Bags/ Drums of different types of premix are coded with Bar codes.
Each type of premix is first cheaked with the help of scanner by
reading the bar codes and then weinghed acc. to required preset
quality with the help of weighing machine.this m/c is attached to the
computer in which all the formulas of different mix are saved.
Depending upon mix composition;each mix is weighing in single.two

or three trolleys. Mix Type Mix No. Date of preparation and trolley no.
is marked on each trolly
After weighing these trolley are moved to LODGIGE MIXER for mixing .
Mix cycle time depends upon mix.type.
CRITICAL POINT :
Mix self life to be measured from date of production of
mix .(Generaly it is 15 days for each mix)
After the mix is ready 2 type of test is done :

1. Bulk volume
2. Density
Types of Material Used In Friction Matertial :
1) Binders ( resin)
2) Metals ( Copper ; brass )
3) Ruber
4) Lubricant
5) Fibers
Product Requirement:
2) Densirty
3) Moisture
4) Bulk volume
Process Requirement:
2) Homogenius mix
3) Proper M/C.
4. Calibration
Calibration is that department in which we check various the

instruments.
Few Calibration instruments are :

1.Vernier Caliper:
Principle:
It is uses two scales one fixed and the other is moveable, then
the difference between these two scales can be utilized to enhance the
accuracy of measurement.
1. Digital :
Vernier Range : 0 ~ 300
Least Count : 0.01 mm
Manufactured by : Mitutoyo
2. Mechanical :

Least count of vernier :

L.C = Smallest division on main scale
Total number of division on vernier scale
= 1
50
= 0.02 mm
2.Dead weight tester:
Aim:
To calibrate the pressure gauge with the help of dead weight
pressure gauge.
Detail:
Make : Ravika
Range : 0~ 400 kg/cm2
Pressure gauge Type:

1. Pneumatic pressure gauge : Calibration by low range
pressure.
2. Hydraulic pressure gauge : Calibration by high range
pressure.
3.Micro meter:
Principle:
It works on the principle of movement of nut and srew.
1. Digital :
Micro meter : 0.25 mm

Manufactured by : Mitutoyo

2. Mechanical :
L.C = Smallest division on main scale
Total number of division on circular scale
5. DUCK AUDIT
PURPOSE
It is carried out after the final manufacturing stage. The

aim is to prevent defective products being shipped to
customers.
EQUIPMENTS:
Vernier Calliper
Tripod
Micro meter

Puppy dial
Height gauge
Surface Plate
PROCEDURE:
THICKNESS OF BACK PLATE
PARALLELISM OF PAD
a) Place the pad on the tripod.

b) Exert the pressure on the puppy dial and set the
reading zero of the puppy dial.
c) Move the probe of puppy dial on the pad and note
down the deflection of the pointer of puppy diaL
OVERALL LENGTH OF BACK PLATE (A-

DIMENSION)
3. Place the back plate b/w the vernier's jaws.

4. Check overall length without disturbing the back plate.
MEASUREMENT OF 'B' DIMENSION
2. Check 'B' dimension of back plate with inside jaws of vernier

caliper.
VISUAL
Check the pad for pip flairing i.e.
a) flairing should not damage the shim.
b) It should not have any burr or chip.
c) Flairing should be done with the centre of pip.

d) Clip should not be tappered with its location on the
pad.
Check the pad for shim pasting i.e.
a) shim should be stick properly on the pad.
b) It should not be pasted taper.
c) It should not be torn or wear out during pasting.
d)
INSPECTION:
Dimensional Inspection:
1. Thickness
2. Parallism
3. Groov Land
Material Test:
1. Density
2. Porosity
3. Acetone Extruction
4. Shear Strength
5. Hardness

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MANUFACTURING OF DISC BRAKES PADS

Department of Mechanical Engineering

Swami Vivekananda Group Of Institutes, banur, Punjab 2

Swami Vivekananda Group Of Institutes, banur, Punjab 2

Today is the world of competition. In every sphere of life there is

Swami Vivekananda Group Of Institutes, banur, Punjab 2

having a complete and immense knowledge of what their customers, employees

employees. Prevention is better than cure is an old time textured saying.

marketing strategies. The present report studies the management problems at

the satisfaction level of employees of different departments like production ,

planning and control etc.

This report is largely based on interview of executives in different departments,

which are in touch with these problems.

In addition to this secondary data is obtained from handbooks published by

Roulunds Braking (India) Pvt. Ltd. and its official site .

Swami Vivekananda Group Of Institutes, banur, Punjab 2

Mr. B.Rameshan Mr.Neeraj sharma

I am deeply indebted to Mr. Neeraj sharma (D.G.M Production)

I offer my special heart fully thanks to Mr.T.P.Singh

My sincere thanks and regards to following persons to provide

1. Mr. S K YOGI (MD)

Swami Vivekananda Group Of Institutes, banur, Punjab 2

Roulunds Braking (India) Pvt. Ltd. is a company registered under the

Roulunds Braking (India) Pvt. Ltd. is leading manufacturer of Disc Brakes

The company is continuously supplying its friction material to highly

The company is a wholly owned subsidiary of MAT (Midwest-Air

Swami Vivekananda Group Of Institutes, banur, Punjab 2

About the Roulunds Braking

ROULUNDS BRAKING product portfolio now includes flexible brake

ROULUNDS BRAKING has manufacturing facilities in India, China,

Swami Vivekananda Group Of Institutes, banur, Punjab 2

 Commencement of Production 1998 – 99

 Take over by MAT Group 2003

 Capital Employed 4.96 Crores

 Total Land Area 23850 sq. m.

 Covered Area (Plant & Machinery) 17315 sq.m.

 Average Number of Employees 1000 per month

 Plant capacity 36 Lakhs Disc Brake

Swami Vivekananda Group Of Institutes, banur, Punjab 2

Swami Vivekananda Group Of Institutes, banur, Punjab 2

Swami Vivekananda Group Of Institutes, banur, Punjab 2

1. IQC ( Incoming Quality control )

1. IQC ( Incoming Quality control )

Incoming Quality control is the most important department in any

Swami Vivekananda Group Of Institutes, banur, Punjab 2

1) Fitment of back plate in tool during pressing

Swami Vivekananda Group Of Institutes, banur, Punjab 2

All materials, Parts and service relevant to space activities must be

Flow of Incoming Inspection:

1. Receive the material from store department in specified format

Swami Vivekananda Group Of Institutes, banur, Punjab 2

For all material movement activities ERP SAP.

INSTRUMENTS USED IN INSPECTION

MATERIAL IDENTIFICATION NUMBER

Swami Vivekananda Group Of Institutes, banur, Punjab 2

We are receiving back plates as per Drawing.

1.VISUAL INSPECTION : In visual inspection we check,

Swami Vivekananda Group Of Institutes, banur, Punjab 2

2.DIMENSIONAL INSPECTION: In Dimensional

The critical dimension for back plate are………….

1) A dimension (Total length of back plate).

Our inspectors make inspection report on specified format and

Swami Vivekananda Group Of Institutes, banur, Punjab 2