INDUSTRIAL

TRAINING REPORT
ON

Aluminium Castings, Clutches and Brakes

Submitted in the partial fulfilment for the award of Bachelor of Technology in

Mechanical Engineering

Submitted To Submitted By
Mr. Rajan Garg Tarun Ahlawat
H. O. D. Roll No. 3407306
Mechanical Engineering 3rd Year Mech. Engg

Department of Mechanical Engineering

S.D. Institute of Technology and Mgmt.
Israna-132107, Panipat
(Affiliated to Kurukshetra University, Kurukshetra )
 PREFACE

The importance of industrial training needs no emphasis. One of the characteristics of modern scenario is
the increasing rapidity of change. This intensifies the need for study, adaptation and training. For an
engineering student the practical training is as important as the theoretical knowledge and sometimes
more than the theory part. The practical training not only makes a student familiar with the atmosphere
and conditions of industry but sufficiently increases his/her knowledge by providing a sense of
confidence and motivation. The main object of all industrial trainings is to prepare an individual so that
he/she can accomplish his/her task efficiently and effectively and can take up and handle jobs of higher
responsibility. Training is an act of increasing the knowledge and skills of an employee for doing a
particular job. The major out come of training is learning. A trainee learns new habits, refined skills and
useful knowledge during the training that helps him/her as improved performance. Training enables an
individual to do his/her present job more efficiently and be prepared for higher level job. Training is a
planned programme designed to improve performances and bring about measurable changes in
knowledge, skill, attitude and social behaviour of an individual.

I personally feel proud and happy in writing this training report that I have completed my training in such
a good organisation which taught me so many useful things.
 ACKNOWLEDGEMENT

I feel immense pleasure in completing this training and submitting this final report. The whole internship
period with ASK Automotive Pvt. Ltd. has been full of learning and a sense of contribution towards
increasing the practical knowledge. I would like to thank Mr. Rajesh Katariya (Manager HR) for
giving me the opportunity to complete my training in such a good organisation.

A successful training can never be completed by the efforts of a single person, but it also demands the
help and guardianship of some conversant person who helped the undersigned actively or passively in
completion of successful training. During the actual training Mr. Devender Sharma (Head Training
Department) has been a source of inspiration through his constant guidance, personal interest,
encouragement and help. I would like to convey my sincere thank to him.

I also take this opportunity to thank Mr. Govind Kaushik (Supervisor) and all those people who made
this experience a memorable one.

Tarun Ahlawat

CONTENTS
1. PREFACE

2. ACKNOWLEDGEMENT

3. CERTIFICATE

4. INTRODUCTION

5. ORGANISATION

6. WORK CULTURE

7. PLANT LAYOUT

8. PRODUCTS

9. SECTIONS

10. QUALITY ASSURANCE

11. ALUMINIUM CASTINGS

12. CLUTCHES

13. BRAKE ASSEMBLY

14. BIBILIOGRAPHY

INTRODUCTION
ASK Automotive (P) Ltd. was founded in 1989 by Mr. K. S. Rathee with a vision to achieve excellence
in the field of manufacturing Automotive Components. The company has technical collaboration with the
world leader in friction material M/S. ASK Technical Corporation, Japan.
With its motto of ‘Customer First’ the company grown over the years and presently it has three plants at
different locations in Gurgaon, Haryana.
Through its commitment to innovation, process improvements, quality control and customer service the
company has been able to position itself as a key resource for leading OEMs.
The ASK’s products are in line with the most demanding quality standards. All of ASK’s operation have
secured appropriate Quality Certifications and the Company has received a no of quality and performance
awards from customers
.
The key automotive OEM domestic customers include

The company also export its products to

USA Sri Lanka Dubai

Netherlands Turkey Iran

The company’s sale graph is increasing year by year. The following chart shows that

Latest Sales Graph

INR in MILLIONS
 1
8
1 0
1 6
7 2 1
1 .
4 1 6 0
3 3 0 0
7 .
7 . . 0
7 0
8 . 3 0 0
. 5 0 0
0 0
0
2003-04 2004-05 2005-06 2006-07 2007-08 2008-09

The following few lines show the success story of the company

 1989 Setting up of company

 1994 “Best Vendor Award” from Kinetic Motor

 1998 ISO:9002 Certification

 1999 QS:9000 Certification

“Best Vender Award” from Kinetic Motor

 2001 Signed TCA with ASK Technica Corp of Japan

Setting up of unit II
Setting up of Die Casting facility

 2003 “Challenge India Support Award” from HMSI

 2004 Setting up of unit III

Setting up of Paint Shop
TS: 16949 Certification

 2005 “Best and Fastest Development Award” from HMSI

Setting up of Wheel Assembly facility
”Commendation Certification for Quality and Delivery” from HMSI

 2006 Setting up of In-house Tool Room

 2007 Setting up of Design Centre

 2009 Plan to set unit IV

ORGANISATION
Organisation may be defined as the process of identifying and grouping the work to be performed,
defining and delegating the authority and responsibility and establishing relationship for the purpose of
enabling people to work most effectively together in accomplishing objective.
The ASK Automotive (P) Ltd. has a very good functional organisation. An organisation chart of the
company is shown below

MD

EXECUTIVE DIRECTOR

DIRECTOR

CEO

GM
GM GM GM
SECRETRI
MARKETI MANUFE PERSONN
-AL AND
NG CTURING EL
LEGAL

HESD
HEAD HEAD HEAD
INSURAN HEAD
HEAD HEAD HEAD PURCHAS PRODUCT RECRUIT
CE AND TRAININ-
RECORDS SALES SERVICES ING ION MENT
TAXES G

HEAD
CREADIT HEAD HEAD
AND ADVERTI- QUALITY HEAD HEAD
COLLECT- SEMENT CONTROL DESIGN LABOUR
IONS

Under each head there is one senior engineer and one engineer. Under engineer there are supervisors and
under supervisors there are workers.

WORK CULTURE
 Various activities of ASK group stands towards maintaing 5-S and TQM are being undertaken in the
company for achieving overall excellence. Some of these are listed below:

• The plant has been divide into various zones with each zone having a zonal leader
• The zonal leader is responsible for 5-S activities in his zone
• Periodic 5-S audits are being conducted by the core group
• Concept of TEI has been introduced
• SGIA (Small Group Involvement Activities) teams formed for different activities

ACMA CUSTER AT ASK

PLANT LAYOUT
There are three plants of ASK Automotive Pvt. Ltd. One plant is located at Udhyog Vihar Phase I,
Gurgaon, second plant is located at Fhatepur Nawada, Manesar, Gurgaon, and third plant is located at
IMT Manesar, Gurgaon. I have completed my training at Unit III. The plant layout of unit III is shown
below

GATE NO. 1

STORE FINISHING
P RAW MATERIAL FFFSECTION
A
R
K
I ADM
N BLOCK MACHINING
M G
A SECTION
I
N
G
A
ASSEMBLY PAINT
T DRILLING
SECTION SHOP
E SECTION

P
A
R
K
I ADM
N BLOCK STORE
G TOOL ROOM FINISHED GOODS

GATE NO. 2

LAYOUT OF ASK AUTOMOTIVE PVT. LTD. UNIT III

PRODUCTS
 ASK Automotive (P) Ltd. manufacture products of many types and specifications according to the need
of OEM customers, but still these can be divided into two types
1. Friction Material Products
These are the products which require friction linings on their surface. Main
friction material products are:

• Brake Shoe
• Brake Assembly
• Brake Lining
• Clutch Plate
•

Brake Assembly Brake Shoe

Brake Lining Clutches

2. Aluminium Castings
Aluminium castings include many products like:
• Panels
• Hubs
• Non-Automotive
• Crank Case
• Grip
• Engine Parts

Panels Hubs

Non Automotive Parts Crank Case

Engine Parts
 Grips

All the products manufactured by ASK are not of one specification but based upon the various different
specification given by the different customers.
 SECTIONS

The different sections of unit III are:

1. Raw Material Store

2. Machining Section
3. Drilling Section
4. Finishing Section
5. Paint Shop
6. Assembly Section
7. Tool Room
8. Finished Goods Store

RAW MATERIAL STORE

The raw material required in Unit III comes from Unit II. For brakes the raw material is all components of
shoe brake such as brake shoe, brake lining, back plate, retractor spring etc. For clutches raw material is
clutch plates and for aluminium castings the raw material is unmachined and unfinished castings which
are finished and painted there.

MACHINING SECTION

In machining section all the machines required to do basic machining of any component are available.
The machines available in machining section are:
Lathe Machine
Shaper
Slotter
Drill Machine
Reaming Machine
Boring Machine
Milling Machine
Grinding Machine
Broaching Machine
Power Hacksaw
DRILLING SECTION

The drilling section of the industry is one of the most important sections for quality aspects. The different
parts manufactured by company require many precise drilling operations. To meet the quality standards
the drilling section is equipped with CNC machine tools. The entire drill machines available in drilling
section are CNCs. There are 15 CNC drill machines out of which ten machines are of fixed automation
type and the rest five are used foe flexible programming. The basic idea behind using CNC machines is
the required accuracy. Also the computer readily and easily programmed, therefore, the system is very
flexible. The machine can manufacture a part followed by other parts of different design.

FINISHING SECTION
The finishing section is fully equipped with the machines and technology required to control the surface
finish of the components. The surface finishing specially required for the castings is done in this section.
Whatever may be the manufacturing process, an absolutely smooth and flat surface can not be
obtained. There are so many irregularities present on the surface of the component which not only give
a bad look to the component but provide a base for corrosion and scale etc to occur. To save metal
from these problems surface finishing is required. All the surface finishing processes can be performed
in the finishing section such as
Grinding
Lapping
Honing
Buffing
Barrel Tumbling
Barrel Rolling
Super Finishing
Burnishing
Powder Coating
Polishing

PAINT SHOP

ASK has a positive pressurised paint shop with following facilities:

Equipped with humidity controller
Using hydrostatic guns for highest quality of painting
Baking of paint is done in temperature controlled oven to ensure consistency in quality of product
Seven bath pre-treatment plant for chromotising
ASSEMBLY SECTION

The assembly section is the last stage for completion of a component. The assembly section at ASK is a
manual one. Though some of the processes for assembly are carried out automatically but most of the
work is done manually.

TOOL ROOM

The tool room is one of most important section of any industry. At ASK the tool room is equipped with
all the tooling solutions required. The tool room is very capable to support the company goal for
achieving development commitments given to its customers by providing related tooling solutions well
within stipulated time frame. The tool room works to eliminate tool related
Quality Problems
Production Problems
Break Down Problems
in existing and duplicated tooling by advancement through design.
 QUALITY ASSURANCE

The quality assurance department plays an important role in any company as in case of ASK. The main
function of quality assurance department is to verify the quality of any process or product as per ASK
standards. The next function is the development that include
• To develop the vendor
• Good communication with the vendor
• If necessary shot out the problem in a particular component at a vendor’s end

ASK is the India’s first company to be awarded the QS 9000 certificate of approval in its category,
followed by another landmark of achieving certification TS 16949:2002 this ensures that the quality
standard of ASK can match up with the best in world. Some of the major achievements of quality
department are:

• 1994 ‘Best Vendor Award’ from Kinetic Motors

• 1998 ISO:9002 Certification
• 1999 QS:9000 Certification
• 2004 TS:16949 Certification
• 2005 ‘Commendation Certificate For Quality and Delivery’ from HMSI

ACTIVITIES PERFORMED BY QUALITY DEPARTMANT

• Receipt Inspection
• In process Inspection
• Final Inspection
• Vendor Development
• Customer Complaint
• Maintain and Implementation of Quality System
• Internal Audits
ORGANISATION STRUCTURE OF QUALITY CONTROL DEPARTMENT

H. O. D.

ENGINEER

BOUGHT OUT FINAL

LINE AUDITORS
INSPECTORS AUDITORS

RECIEPT INSPECTION

RECEIVED FROM
SUPPLIER

RECEIVED
INSPECTION

GREEN CARD RED CARD YELLOW CARD

OK QUALITY REJECT HOLD

Sent back to supplier for corrective action report to get back from supplier

IN LINE INSPECTION
 INLINE
INSPECTION

FIRST OFF SETTING

LINE AUDIT
APPROVAL

-M/C CHANGE
ONCE IN TWO
SHIFT START -NEW PART
HOURS
-MOULD CHANGE

VISUAL AND PROCESS

VISUAL
BONDING CHANGE

VISUAL,
DIMAENSIONAL
AND BONDING

ALUMINIUM CASTINGS
 Aluminium castings are one of the main products manufactured by ASK Automotive Pvt. Ltd. These
castings are generally the engine components. The different castings manufactured by ASK are shown
below:

Panels Hubs

Non Automotive Parts Crank Case

Engine Parts

The die castings manufactured by ASK have excellent surface finishes that are consistent dimensionally
with the precision features and minimum draft. ASK Automotive Pvt. Ltd. produces efficiently
engineered and high pressure aluminium castings. Die casting alloys are generally non ferrous and there
are a large no available with a wide range of physical and mechanical properties to cover almost every
application a designee might need.
The flexible automation technologies available at ASK include:
• Quick change tooling for standard machines
• Modular fixtures and jigs
• High speed capability, multi functional, excellent quality and well processed design
• Internet systems transmitting information between engineering and management
• In process gauging and embedded inspection devices for quality control
• Recycle systems for achieving green products and a healthy work environment
Key die casting specifications include:
• Materials - Aluminium and Aluminium Alloys
• Al - 7 kg max. weight and 950 sq cm max. size
• Finishes - Spray Painting
• Complete range of secondary operations – CNC machining, drilling, assembly services
• All factories QS:9000 and TS 16949 certified
• In house mould/tool design and fabrication capabilities
• Central melting furnace of capacity from 80 to 660 tonnes

The casting of these products is prepared in Unit II and these are brought here for finishing. Here at Unit
III the castings from 20g to 2.50 kg of weight are duly machined, finished and painted. Machining of
casting involves basic operations like turning, milling, slot cutting, drilling etc and the operations are
performed on the machines available in different sections of unit. After completion of machining work
the castings are sent to the finishing section. In the finishing section first of all the components are
cleaned for all types of chips and burrs removal. Then it is completely cleaned for all types of foreign
materials like dust, dirt, greases, oil etc. after cleaning the component is painted in paint shop. Cleaning
and painting of casting is a long process and completed in following stages:

STAGE I - FINISHING

Stage one includes surface finishing processes

.
SURFACE FINISHING

All types of surface finishing processes are available in finishing section and can be used according to
requirement. These are:
• Grinding
• Lapping
• Honing
• Buffing
• Barrel Tumbling
• Barrel Rolling
• Burnishing
• Powder Coating
• Polishing etc.

For aluminium castings the most used process is burnishing.

BURNISHING

Burnishing operation is the process of getting a smooth and shining surface by contact and rubbing of the
surface against the walls of a hard tool. It is a finishing and strengthening process. Burnishing is basically
a cold surface plastic deformation process which improves the surface finish and induces the surface
compressive residual stresses, thus improving the fatigue life of the component. In the process of
burnishing a cylindrical roller of hardened steel or cemented carbide is made to roll against the
component surface. Hole burnishing is preferred with multi roller tools on drill presses, turret lathes,
horizontal bores, unit built machines and automatic lathes. Burnishing raises the hardness of the surface
by 20 to 50% and its wear resistance by 1.5 to 2 times.

STAGE II - CLEANING

Stage II includes surface cleaning processes.

SURFACE CLEANING

Surface cleaning is necessary before painting. It provides a base for paint or any other coating material to
stick with surface firmly. First of all the component is cleaned by wire brush and cotton waste and then
surface cleaning of castings is done by following processes:

ALKALINE CLEANING

In this method the parts are cleaned by dipping them in aqueous solution of alkaline silicates, caustic soda
or similar cleaning agents. Some type of soap is added to aid in emulsification. This method satisfactorily
removes greases and oil. The cleaning action is by emulsification of oils and greases. Special washing
machines are employed in lot and mass production. Washing machines may be of single, double or multi
chamber type.
 CHEMICAL POLISHING

Chemical polishing is one of most important surface finishing process for aluminium and its alloys. In
this process the metallic objects are immersed in baths of selected acids. During the process, certain
amount of metal, mainly from peaks is dissolved, producing a bright surface, without the formation of
etched pattern. For chemical polishing of aluminium alloys the most successful of the solutions used
contain phosphoric, nitric and sulphuric acids. The production cycle consists of following steps

. Immerse for 1 to 3 minutes at 100°C

. Remove and rinse in hot water (70°C) to remove viscous film formation
. Rinse in a mixture containing equal amounts of water and 1.42 sp. gr. nitric acid at room temp
. If anodising required, rinse in cold water
. If lacquering required, rinse in hot water
The resultant surface finish will be of the order of 0.45 to 0.50 with a high reflection factor of 88%

STAGE III - PAINTING

The IIIrd stage is consists of painting process. After cleaning the surface a coat of paint is applied on the
surface of component as explained below:

Metal parts are painted to protect their surfaces against the corrosive action of surrounding medium and
also to improve their appearance. The process of coating with paints and varnishes is carried out in three
stages: (i) preparation of the surface to be coated, (ii) painting and (iii) drying with finishing.

. SURFACE PREPARATION

The castings with clean surfaces are first prepared by applying primers like oil varnish, Oleo-
bituminous, water soluble and nitro soluble primers. The primed surface is then treated with filler,
whose layer should be as thin as possible. Oil varnish fillers and quick drying pyroxylin fillers are
commonly used.
ii. PAINTING
Painting is done by applying one or several layers of paint. Oil and enamel paints and varnishes are
used for this purpose. Nitro enamels dry in 30 to 40 minutes; after drying these form a hard glossy
layer. Oil and spirit enamels dry for 24 to 48 hours
 Methods of Painting

The various methods of industrial painting are

• Brush Painting
• Spray Painting
• Dip Coating
• Flow Coating
• Painting in Drums

At ASK spray painting is used as painting method.

Spray Painting

The method consists in applying fluid paint in atomised form. This method is most common and
productive, but requires premises equipped with exhaust devices and spraying equipment. This method
can be used in the following four ways:

. Mechanical Spraying

In this method the paint is delivered to a spray gun by a pump.

. Air Spraying

In this method the paint is sprayed by a jet of compressed air which carries the paint mist to
the surface to be painted. The method is capable of coating 30 to 80 of surface per hour, but
losses are high (40 to 50 %).

. Air Less Spraying

In this method, paint heated to 70 to 90°C is forced through a nozzle at a pressure of 2 to 4

N/mm² and so sprayed. The method allows the use of highly viscous paints, which cuts the
solvent requirements drying time. The production rate can be 50 – 200 m² of surface per hour
and paint losses amount to 25 – 50%.

. Electrostatic Spraying
 In this method, a negatively charged sprayer delivers paint which gets into the surface of a
positively charged metal part being painted. The charging is being provided by a high voltage
constant current source. The paint losses are less than 5%. The method makes it possible to
improve working conditions, to provide for fairly high productivity (50 m² of surface per
hour) and for the possibility of developing a fully automated painting process.

iii DRYING

After being painted, the parts undergo drying. The quality of paint coatings depend on the
method of drying. Drying is a complex chemical process involving evaporation of the solvent and
oxidation or polymerization of the coating film. Drying can be natural or artificial.

The natural or air drying is carried out at a temperature of 18 to 25°C over a long time. The
artificial drying makes it possible to speed up solidification of the coat and also to greatly improve
its quality.

The most common method of artificial drying is by convective heating. The drying is carried out in a
closed chamber which is air-heated by gas, electricity, or steam to temperature of 55 to 220°C or by
means of a reflector equipped with banks of special electric lamps. The latter method takes only from
one fourth to one half as much time as hot air drying method. Other drying methods utilize high
frequency current (induction heating) and infrared rays.

CLUTCHES
 A clutch is the device used in transmission line between the engine and gear box which transmits the
rotary motion of engine shaft to the gear box shaft at desire. It is the device which makes or breaks
contact between the engine and gear box.

Clutch Plates

FRICTION MATERIAL FOR CLUTCHES

Mainly the friction materials for clutches are of three types:

1. Millboard Type
2. Moulded Type
3. Woven type

MILLBOARD TYPE

This is only asbestos sheet treated with certain impregnants. From this sheet are then facing discs cut
according to different size requirements. This is the cheapest available type and is quit satisfactory.

MOULDED TYPE

This is made by mixing asbestos fibres with a suitable binding material, heating to a certain well
defined temperature and then moulding in dies under pressure. Metallic wires are also sometimes used
to improve wearing qualities.
This type of facing is more dense and capable of taking heavier working loads. However there is one
disadvantage that each clutch facing has to be moulded separately.
 WOVEN TYPE

This type consists of a cloth impregnated with certain binders. The cloth may either be woven like
ordinary cloth with wrap and weft or by winding the fibres in circumferential direction only.

In the solid woven variety, the cloth is woven just to the required thickness. In case of laminated
variety, the layers of cloth one upon the other are held together by a binder. Stitches are provided in
addition to the binder.

COMMON CLUTCH FACING MATERIALS

Organic friction materials are the most common types of clutch facing materials. These are:

• Leather

Dry leather on iron has coefficient of friction of 0.27.

• Cork

Cork on dry steel or iron has coefficient of friction of 0.32.

• Fabric

Good quality fabric materials have coefficient of friction of about 0.4. But they can not be used at
high temperatures.

• Asbestos

Asbestos facing has a coefficient of friction of about 0.2. However it has got anti heat
characteristics.

• Reybestos and Ferodo

 These asbestos based facings have a coefficient of friction of about o.35 but obsolete due to health
risk possessed by asbestos.

• Non Asbestos Based Clutch Facing

These are made of man made fibre yarns such as glass fibre, mixed with special rubber compound
to improve frictional performance, firmly locked with the elastomer based novalac binder and
moulded with pressure and heat. Some materials may also be woven and may contain brass wires.
Examples of this type are SW3-AF, HWK 200 etc.

REQUIREMENT OF GOOD CLUTCH FACING

• Good wearing properties.

The wear of the clutch facing depends upon the rubbing speed and intensity of pressure. For
maximum life the rubbing speed at the time of engagement should not exceed 30 m/s while
pressure intensity should not exceed 100 kPa.
• Presence of good binder in it.
• Cheap and easy to manufacture.
• High coefficient of friction.
• High resistant to heat. A good clutch facing can withstand temperature of about 330°C.

BRAKE ASSEMBLY
 Brakes are the devices used to control and reduce the speed of vehicle and to stop the vehicle when
required. ASK manufactures shoe breaks and disc brakes.

BRAKING REQUIREMENTS

1. The brake must be strong enough to stop the vehicle within a minimum distance in an
emergency. But this should also be consistent with safety and vehicle must not skid.
2. The brake must have good antifade characteristics. This requirement demands that the cooling
of brake should be very efficient.

COMPONENTS OF BRAKE

The basic components of a brake are:

• Brake Drum or Cover
• Brake Shoe
• Brake Lining
• Retractor Spring
• Adjuster and Expender etc.

Brake Shoe Brake Lining

 Brake Assembly

REQUIREMENTS OF BRAKE DRUM

1. It should provide a surface having good anti-wear qualities.

2. It should allow the optimum heat transfer.
3. It should have sufficient strength but minimum weight.
4. It should be able to accommodate within the wheel space available.

BRAKE SHOE

The brake shoes are made of T- section and are covered to match the inside curvature of the drum. The
ends may be flat, curved or having a semi circular groove to locate the expander. They are made of
cast iron or steel. Aluminium shoes have also been tried because of their good thermal conductivity,
but their use has been very limited probably due to low values of strength and stiffness of aluminium.
The modern vehicles employ pressed steel brake shoes.

BRAKE LININGS

There are two main types of brake linings:

1. SOLID WOVEN TYPE

The asbestos based non metallic linings have in general, have an average coefficient of friction of
0.4 up to around 260°C and fade is not serious up to 300°C. Their maximum temperature
resistance is around 350°C.
2. MOULDED TYPE

This type is moulded directly from the ‘mix’, which contains asbestos fibres, together with resin
powders and fillers. The average coefficient of friction with this type of lining is 0.4 and
temperature resistance varies from 400 to 450°C. They have good anti- fade and anti-wear
characteristics.
The different moulded type brake linings used are:

• Ferodo 2629 F

This is for use on drum type brakes.

Recommended Operating Range
Unit Pressure 70-690 kN/m²
Max. Rubbing Speed 18 m/s
Max. Temperature 400°C
Max. Continuous Temperature 175°C

Bonding
Common adhesives may be used for bonding, but for better results thermosetting adhesives
should be employed.

Recommended Mating Surface

Good quality, fined grained cast iron.

Technical Data
Ultimate Tensile Strength 15.18 MN/m²
Ultimate Compressive Strength 6.8 MN/m²
Ultimate Shear Strength 6.9 MN/m²
Thermal Conductivity 0.67 J/m s/°C
Brinell Hardness 12
Friction Coefficient 0.41 (for design purpose)

• Rane 9011 DC

This is for use of commercial vehicle drum brakes.

 Technical Data
Density 190 g/cc
Hardness (Rockwell ‘L’ Scale) 90
Gross Braking Strength 45 MPa
Tensile Strength 21.6 MPa
Shear Strength 15.7 MPa
Compressive Strength 107.9 MPa
Max. Continuous Operating Temperature 250°C
Max. Transient Operating Temperature 350°C

DISC BRAKE PADS

Ferodo 2449 E rigid moulded friction material is used for disc brake pads. It is light brown in colour,
having a random fibre asbestos base and containing copper particles. The material has good resistance
to fade and wear.

Recommended Operating Range

Unit Pressure 0.35-5.2 MPa
Max. Rubbing Speed 24 m/s
Max. Temperature 550°C
Max. Continuous Temperature 250°C

Recommended Mating Surface

Good quality, fine grained pearlitic cast iron.

Technical Data
Modulus in Compression 830 MPa
Ultimate Shear Strength 11 MPa
Thermal Conductivity 1.23 J/m s°C
Brinell Hardness 14
Friction Coefficient 0.37 (for design purpose)

The asbestos free disc pad material is Rane 6717 H.

 BIBILIOGRAPHY

1. A Text Book of Production Technology by P. C. Sharma

2. Automobile Engineering by Dr. Kirpal Singh

3. Elements of Workshop Technology by S. K. Hajra Choudhary

4. Industrial Engineering and Management by Dr. O. P. Khanna

5. www.askbrake.com