Theoretical and Experimental Study on the Feasibility of Local Manufacturing of Brake Discs

Abstract

The disc brake system is one of the most critical safety systems in modern vehicles, as its performance fundamentally depends on the properties of materials used in manufacturing brake discs and friction pads. The local automotive spare parts sector suffers from near-complete dependence on imported products, creating an economic burden and affecting the availability of parts in local markets. This research aims to study the feasibility of locally manufacturing brake discs using cast iron melted in an electric furnace and evaluate its performance compared to commercial imported discs. Two locally manufactured discs were produced: the first without ventilation holes, and the second after adding ventilation holes. Repeated braking tests (60 cycles) were conducted from a speed of 100 km/h to complete stop, measuring wear on the disc and inner and outer brake pads. The results showed that the locally manufactured disc without ventilation recorded the highest wear rates (0.08 mm for the disc, 0.535 mm average for pads), while the locally manufactured disc with ventilation showed wear comparable to the commercial disc (0.03 mm for the disc vs. 0.02 mm for commercial) and outperformed it in brake pad wear resistance (0.09 mm average pad wear vs. 0.215 mm for commercial). The results confirm the feasibility of successful local manufacturing provided that ventilation and precision finishing processes are implemented, with a competitive advantage in extending pad lifespan.