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When having new Bendix disc brake pads fitted to their vehicle, most drivers won’t give much thought to what goes on behind the scenes to ensure their purchase performs at its best not only when fitted, but thousands of kilometres down the road.

Aside from the detailed prototyping and engineering process that each product line goes through during development, Bendix has comprehensive Quality Assurance protocols in place that are systematically applied during the manufacture of all disc brake pads. It’s one of the reasons why Bendix boasts an impressive – and extremely low – eight parts per million in manufacturing defects.

The QA process combines subtle and not so subtle procedures, with pads subjected to a variety of strength testing along with other measures that evaluate dimensional specifications and check the composition of the raw friction materials.

Strength and fit

Shear testing evaluates how well the brake pad’s friction compound is bonded to its backing plate. A shear strength test machine applies hydraulic pressure against the edge of the friction material to a specified level to determine the quality of adhesion. This test is conducted at both ambient temperature and with the part at 300°C to replicate real world operating conditions.

Bendix gives insight into extensive QA processes 1

Shear testing evaluates how well the brake pad’s friction compound is bonded to its backing plate.

Another procedure that also seeks to emulate driving conditions is the compression test, which again uses equipment but this time to simulate brake (caliper piston) applications and check pad displacement under ambient and elevated temperatures of up to 400°C.

Bendix gives insight into extensive QA processes 2

The compression test simulates brake (caliper piston) applications and checks pad displacement under ambient and elevated temperatures of up to 400°C.

To ensure an easy fit and installation when pads are being replaced, a Coordinate Measuring Machine is used to dimensionally check that the pad correctly aligns with the specifications of the engineering drawings. For auxiliary hardware – particularly smaller components – a shadow graph is used to measure these.

Bendix gives insight into extensive QA processes 3

A Coordinate Measuring Machine is used to dimensionally check that the pad correctly aligns with the specifications of the engineering drawings.

Friction material quality and accuracy

With the structural integrity of the pad assured, Bendix’s QA team turns its attention to the friction material. Among the checks is an XRF (X-ray Fluorescence) test that examines the composition of the material and identifies if any inorganic elements are present. This is supported by an acetone test as well as resin testing, specific gravity test and sieve size analysing.

Bendix gives insight into extensive QA processes 4

A technician prepares to check the density of raw material ingredients that will go into a friction material mix

Each of these tests are designed to ensure that along with containing the correct ingredients, that the quantity and particulate size of each raw material element matches the required formula for the corresponding brake pad.

The QA program is finalised with yield testing – Bendix knows the weight of each raw material that has gone into the mix, so the yield should match the combined total of these raw materials. Should a discrepancy arise, there’s a potential issue with the mix and it will be investigated.

Testing frequency

Along with the rigidity of the QA processes, testing frequency is also important and helps minimise the likelihood that an underperforming pad will slip through the manufacturing facility. At Bendix the first 30 batches of raw materials are inspected before moving to skip lot inspections (every five batches or twice a year). For disc pad testing from the production facility, Bendix’s inspection team take samples for evaluation from every batch.

Bendix gives insight into extensive QA processes 5

Test results are compared against specification and engineering drawings before given the all clear.

In the unlikely event that a complaint or error with a brake pad is found by a mechanical workshop, Bendix will investigate every occurrence, to reduce the likelihood of the issue happening again. Bendix’s detailed QA program is one of the reasons workshop professionals can fit Bendix pads with confidence, allowing drivers to put their foot down with confidence.

Bendix gives insight into extensive QA processes 6

Robust QA testing ensures extremely low manufacturing defects across the Bendix Disc Pad range, meaning drivers can put their foot down with confidence.

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  • Bendix Media Release June 2024 PRJ 08599
    (476.66kb)
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