Assessment on Potential Damages of Automotive Brake Caliper Using FMEA Method for the Application of Remanufacturing Process

Abstract

The repair and restoration stage in remanufacturing is one of the vital phases to ensure the remanufactured component is qualified during the testing stage. The reliability of the component can be evaluated at the very early stage of remanufacturing process, by adopting the FMEA method. The FMEA method is a tool that facilitate the evaluation of reliability of component related to potential failures and damages of the component. An automotive brake caliper is selected as a case exemplary in this study. The FMEA method will be used to confirm the applicability of DED process as one of the repair processes where not all type of failures or damages are suitable to be repaired through DED process. Therefore, this study presents the identification of potential damages or failures of brake caliper and further, analyse the reliability of the component and identify the possible corrective action can be taken. The study shows that the failure modes of a brake pad is irreparable cases that requires part replacement whilst for brake caliper housing shows as having some potential to be repaired using DED process. However, further investigation related to the strength of the component is required to support the FMEA results.

Failure-based design validation for effective repair of multi-metal additive manufacturing: the case of remanufacturable brake caliper

“…In addition, the ndings from literature and interview are further veri ed by applying FMEA tools. A recent study by Aziz et al [33] has discussed in detail the FMEA of the same brake caliper model. FMEA is a quality tool that evaluates potential damages or failures experienced by the components by giving a rating to each of the damages with regard to their severity, occurrence and detection.…”

“…FMEA is a quality tool that evaluates potential damages or failures experienced by the components by giving a rating to each of the damages with regard to their severity, occurrence and detection. The FMEA developed by Aziz et al [33] only focused on DED. However, the proposed study will consider DED and PBF as the repair options in the new FMEA (Table 3).…”

“…Fractured failure refers to a brittle fracture that occurred because of high and rapid impact experienced by the brake caliper housing component. The descriptions of each damage listed in Table1are further described in Table 4[33].…”