Optimization of tribological parameters for a brake pad using Taguchi design method

In this study, the weight loss of brake pad in automotive brake system was investigated using Taguchi’s method. Wear tests of the brake pad versus cast iron disk were carried out for a dry sliding condition in a so-called a pad-on-disk rig. The wear tests were realized at the sliding speeds of 7, 9, and 11 ms−1 and under the pressures of 0.5, 1, and 1.5 bars. The obtained lowest weight loss for the brake pad contains the copper flake volume fraction of 20 % by weight under the same test conditions. The experimental results are transformed into a signal-to-noise (S/N) ratio using Taguchi method. Volume fraction of copper flake, pressure, and interaction between volume fraction of copper flake and pressure exert a great effect on the weight loss, at 58.11, 16.35, and 20.86 %, respectively. The estimated S/N ratios of the weight loss, using the optimal testing parameters, were calculated and a good agreement was observed between the predicted and actual weight loss, with a confidence level of 99.5 %.