The Application of Mold Release Agent in Brake Shoes Production
In the production process of brake shoes, the use of a Mold Release Agent in brake shoes mixtures and mixes has become an integral part. It plays a crucial role in the manufacturing of brake shoes friction materials, bringing both advantages and disadvantages.
Advantages
- Improved Demolding Efficiency
- A Mold Release Agent significantly enhances the demolding efficiency. In a production line where brake shoes are mass – produced, without a release agent, the average time taken for demolding a single brake shoe is about 30 seconds. However, after using a high – quality Mold Release Agent, this time can be reduced to 10 – 15 seconds. This reduction in demolding time not only increases the production speed but also allows for higher production volumes. For example, a factory that produces 1000 brake shoes per day can potentially increase its output to 1500 – 2000 brake shoes per day with the help of a release agent.
- Surface Quality Enhancement
- It greatly improves the surface quality of brake shoes. Brake shoes produced without a Mold Release Agent often have rough surfaces with a surface roughness of around 1.5 – 2.0 micrometers. In contrast, when a release agent is used, the surface roughness can be reduced to 0.5 – 1.0 micrometers. A smoother surface is beneficial as it reduces the risk of uneven wear during the braking process, ensuring more consistent friction performance.
- Extended Mold Lifespan
- The use of a Mold Release Agent can extend the lifespan of the molds. Molds used for brake shoe production without a release agent may need to be replaced after 500 – 800 production cycles due to wear and adhesion issues. However, with the application of a release agent, the mold lifespan can be extended to 1500 – 2000 production cycles. This not only reduces the mold replacement cost but also minimizes production downtime for mold changes.
Disadvantages
- Potential Contamination
- There is a risk of contamination of the brake shoes friction materials. Some Mold Release Agents, if not properly selected or applied, can leave residues on the surface of the brake shoes. These residues may affect the friction properties of the brake shoes. Research has shown that in about 5 – 10% of cases where low – quality release agents are used, the friction coefficient of the brake shoes can deviate by ±0.05 from the desired value, which may lead to inconsistent braking performance.
- Cost Considerations
- High – performance Mold Release Agents can be relatively expensive. The cost of a high – quality release agent can add about \(0.5 – \)1.0 to the production cost of each brake shoe. For a large – scale brake shoe manufacturer that produces millions of brake shoes annually, this cost can accumulate to a significant amount. Additionally, the need for proper storage and handling of the release agent to maintain its effectiveness also adds to the overall production cost.
In conclusion, the application of a Mold Release Agent in brake shoes production offers notable advantages in terms of demolding efficiency, surface quality, and mold lifespan. However, the potential for contamination and cost implications must be carefully managed to ensure the overall quality and cost – effectiveness of brake shoe production.