Title: Brake pads binder composition optimisation for enhanced performance and durability using Taguchi's method

Authors: Aqleem Siddiqui; Badal Kudachi; Vishal G. Salunkhe; Amit Malgol

Addresses: Department of Mechanical Engineering, 'Agnel Charities' Fr. C. Rodrigues Institute of Technology, Vashi, Navi Mumbai, 400703, Maharashtra, India ' Department of Mechanical Engineering, 'Agnel Charities' Fr. C. Rodrigues Institute of Technology, Vashi, Navi Mumbai, 400703, Maharashtra, India ' Department of Mechanical Engineering, 'Agnel Charities' Fr. C. Rodrigues Institute of Technology, Vashi, Navi Mumbai, 400703, Maharashtra, India ' Department of Mechanical Engineering, 'Agnel Charities' Fr. C. Rodrigues Institute of Technology, Vashi, Navi Mumbai, 400703, Maharashtra, India

Abstract: Binders are critical components in brake pad formulations, significantly influencing their performance, durability, and lifespan. Understanding the interaction between binder variations and other brake pad constituents is essential for optimising braking efficiency and material behaviour. The test rig features a ventilated brake disc driven by a motor and employs a pneumatic system to simulate real-world braking conditions. Brake pad samples are prepared by varying the percentage of binder materials, and an experimental design was formulated using an orthogonal array generated with Taguchi's method. Comprehensive tests, including wear analysis, shear strength, Rockwell hardness, and acetone extraction, are conducted in order to optimise brake pad performance. Results indicated that samples with high phenolic and minimal epoxy content exhibited superior wear resistance, while high epoxy concentrations negatively impacted mechanical properties and density. The results are analysed in MINITAB to determine the optimal binder composition for improved braking efficiency. This study investigates brake pads used in disc brakes and explores the potential for optimising their composition to improve braking efficiency and performance.

Keywords: binder; MINITAB; disc brakes; cashew nut shell liquid; CNSL; modified epoxy; Taguchi's method.

DOI: 10.1504/IJSURFSE.2026.151881

International Journal of Surface Science and Engineering, 2026 Vol.20 No.1, pp.96 - 111

Received: 03 May 2025
Accepted: 30 Oct 2025
Published online: 24 Feb 2026 *

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