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.