Structural Integrity and Durability Assessment of Composite Brake Pads Using Finite Element Simulation

The demand for durable and environmentally sustainable brake pads has driven increasing interest in composite materials for automotive applications. This study presents a numerical assessment of the structural integrity and durability of a composite brake pad using finite element simulation techniques. Finite Element Analysis (FEA) was performed in ANSYS to evaluate key mechanical responses, including von Mises stress, principal stresses, and total deformation under representative braking loads. The composite formulation comprised phenolic resin as the binder, graphite as a solid lubricant, aluminum oxide as an abrasive, and agro-mineral fillers including coconut fiber, palm slag, and sawdust, selected for their functional performance and sustainability benefits. Simulation results revealed a maximum equivalent stress of 1.3981 × 10⁷ Pa (13.98 MPa) and a minimum principal stress of −1.90 × 10⁵ Pa (−0.19 MPa), with stress concentrations localized primarily within the frictional contact region. The total deformation ranged from 1.68 μm to 0.017 μm, indicating very low displacement and high stiffness under operational loading conditions. These findings confirm that the composite brake pad maintains structural stability and operates within safe stress limits, demonstrating suitability for repeated and prolonged braking scenarios. Overall, the study validates the effectiveness of simulation-based evaluation in predicting brake pad performance and highlights the potential of agro-based composite materials for reliable and sustainable automotive braking systems.