Finite element modelling for the investigation of in-plane modes and damping shims in disc brake squeal

Squeal propensity of the in-plane modes and the constrained-layer type damping shims for disc brake system is investigated by using the finite element method. Theoretical formulation is derived for a rotating disc in contact with two stationary vibrating pads attached to the damping shim components. By the conversion from the theoretical to FE brake model, the full equations of motion for the actual disc brake system describes the disc rotation, the in-plane friction characteristics and damping shims in association with squeal vibration. It is concluded from the results that the in-plane torsion modes can be generated by the negative friction slope, but they cannot be controlled by the damping shims. The in-plane radial mode is also investigated and found to be very insensitive in squeal generation.     

Analysis of disc brake squeal using the complex eigenvalue method

A new functionality of ABAQUS/Standard, which allows for a nonlinear analysis prior to a complex eigenvalue extraction in order to study the stability of brake systems, is used to analyse disc brake squeal. An attempt is made to investigate the effects of system parameters, such as the hydraulic pressure, the rotational velocity of the disc, the friction coefficient of the contact interactions between the pads and the disc, the stiffness of the disc, and the stiffness of the back plates of the pads, on the disc squeal. The simulation results show that significant pad bending vibration may be responsible for the disc brake squeal. The squeal can be reduced by decreasing the friction coefficient, increasing the stiffness of the disc, using damping material on the back plates of the pads, and modifying the shape of the brake pads.     

Brake squeal reduction of vehicle disc brake system with interval parameters by uncertain optimization

An uncertain optimization method for brake squeal reduction of vehicle disc brake system with interval parameters is presented in this paper. In the proposed method, the parameters of frictional coefficient, material properties and the thicknesses of wearing components are treated as uncertain parameters, which are described as interval variables. Attention is focused on the stability analysis of a brake system in squeal, and the stability of brake system is investigated via the complex eigenvalue analysis (CEA) method. The dominant unstable mode is extracted by performing CEA based on a linear finite element (FE) model, and the negative damping ratio corresponding to the dominant unstable mode is selected as the indicator of instability. The response surface method (RSM) is applied to approximate the implicit relationship between the unstable mode and the system parameters. A reliability-based optimization model for improving the stability of the vehicle disc brake system with interval parameters is constructed based on RSM, interval analysis and reliability analysis. The Genetic Algorithm is used to get the optimal values of design parameters from the optimization model. The stability analysis and optimization of a disc brake system are carried out, and the results show that brake squeal propensity can be reduced by using stiffer back plates. The proposed approach can be used to improve the stability of the vehicle disc brake system with uncertain parameters effectively.     

Automotive disc brake squeal

Disc brake squeal remains an elusive problem in the automotive industry. Since the early 20th century, many investigators have examined the problem with experimental, analytical, and computational techniques, but there is as yet no method to completely suppress disc brake squeal. This paper provides a comprehensive review and bibliography of works on disc brake squeal. In an effort to make this review accessible to a large audience, background sections on vibrations, contact and disc brake systems are also included.     

Double pulsed holography used to investigate noisy brakes

The vibrational characteristics of a noisy passenger car disc brake have been studied using the double pulsed holographic technique which has been developed to allow three orthogonal visual images of a vibrating brake system to be recorded simultaneously. These images show the disc to be vibrating in a bending mode whereas the pad is seen to be excited in a variety of modes such as bending, torsion, and often a combination of both. The development of the technique includes alternative ways of triggering the laser and typical results from the application of these differing methods are also included along with mechanical signals which confirm the visual interpretations. Final results, using a laser trigger delay technique, show that the disc mode waveform rotates about the disc at a rate equivalent to the frequency of vibration divided by the diametral mode order. Early work on a passenger car drum brake is also introduced, this complementing commercial ‘noise fix’ solutions and a proposed theoretical model.     

ANALYSIS OF DISC BRAKE NOISE USING A TWO-DEGREE-OF-FREEDOM MODEL

Although a brake pad and disc have many modes of vibration, when it is unstable and hence noisy then frequently only a single mode of the complete system contributes to the vibration. In this condition, only a few modes are required to model the system. In this paper, a two-degree-of-freedom model is adopted where the disc and the pad are modelled as single modes connected by a sliding friction interface. Using this model, the interaction between the pad and the disc is investigated. Stability analysis is performed to show under what parametric conditions the system becomes unstable, assuming that the existence of a limit cycle represents the noisy state of the disc brake system. The results of this analysis show that the damping of the disc is as important as that of the pad. Non-linear analysis is also performed to demonstrate various limit cycles in the phase space. The results show that the addition of damping to either the disc or the pad alone may make the system more unstable, and hence noisy.     

Performances of some reduced bases for the stability analysis of a disc/pads system in sliding contact

The complex eigenvalue analysis is a widely used technique to investigate the stability of a dynamical system with frictional contact. In the case of brake systems, it is the most frequently employed method to study the propensity of the brake to generate squeal noise. When finite element models are considered, iterative solvers are needed to calculate the complex modes and eigenvalues with good precision. In practice, reduced real bases are often used in order to reduce the computational times. However, great attention should be focused on the errors introduced by the reduction, which is rarely done. In this paper, the performances of some reduced bases are investigated in the case of a simple disc/pads system. Bases composed of real coupled modes and bases provided by Component Mode Synthesis (CMS) techniques are tested. An enrichment of these bases is proposed in order to improve the precision of the results. In particular, new rubbing attachment modes are proposed to adapt free-interface CMS techniques to frictional contact. When real coupled modes are used, it is suggested to complete the basis by the static response to a first-order approximation of the friction forces. Applied to the disc/pads model, the different enrichment options allow a reduction of the errors on frequencies, divergence rates and mode shapes by a factor comprised between 10 and 100 without significantly increasing the computational times.     

Modeling of automotive drum brakes for squeal and parameter sensitivity analysis

Many fundamental studies have been conducted to explain the occurrence of squeal in disc and drum brake systems. The elimination of brake squeal, however, still remains a challenging area of research. Here, a numerical modeling approach is developed for investigating the onset of squeal in a drum brake system. The brake system model is based on the modal information extracted from finite element models for individual brake components. The component models of drum and shoes are coupled by the shoe lining material which is modeled as springs located at the centroids of discretized drum and shoe interface elements. The developed multi degree of freedom coupled brake system model is a linear non-self-adjoint system. Its vibrational characteristics are determined by a complex eigenvalue analysis. The study shows that both the frequency separation between two system modes due to static coupling and their associated mode shapes play an important role in mode merging. Mode merging and veering are identified as two important features of modes exhibiting strong interactions, and those modes are likely candidates that lead to coupled-mode instability. Techniques are developed for a parameter sensitivity analysis with respect to lining stiffness and the stiffness of the brake actuation system. The influence of lining friction coefficient on the propensity to squeal is also discussed.     

The method of feed-in energy on disc brake squeal

Brake squeal is studied in this paper by feed-in energy analysis. Based on the brake closed-loop coupling model, a calculation method of feed-in energy for squeal mode is derived. Result of the feed-in energy indicates squeal tendency of the brake system, while formula for calculating it discloses the relation among brake squeal phenomenon and structural parameters, such as frictional coefficient, geometric shape of brake pads, elastic modulus of frictional material, substructure modal shape, etc. The method also helps to analyze the effectiveness of various structural modification schemes attempted to eliminate the squeal noise. Finally, this method is illustrated by application to a typical squealing disc brake.     

Eigenvalue optimization against brake squeal: Symmetry,mathematical background and experiments

Brake squeal is still a challenge for design engineers and scientists. Due to cost reasons for the avoidance of brake noise only passive measures are meaningful for a broad industrial range. Many countermeasures against squeal are based on the introduction of damping, for example by using shims. In the literature on the modeling of brake squeal, the structural properties of the brake disc are most often not considered. It has however been shown analytically and experimentally that the stiffness properties of the disc are important and that splitting of double modes of the disc has a stabilizing effect. This knowledge can be used for structural optimization of brake rotors. The goal of this paper is to exploit the potential and to discuss some mathematical difficulties. Furthermore, experimental evidence for the relation of rotor asymmetry and squeal is given.     

A new treatment for predicting the self-excited vibrations of nonlinear systems with frictional interfaces: The Constrained Harmonic Balance Method,with application to disc brake squeal

Brake squeal noise is still an issue since it generates high warranty costs for the automotive industry and irritation for customers. Key parameters must be known in order to reduce it. Stability analysis is a common method of studying nonlinear phenomena and has been widely used by the scientific and the engineering communities for solving disc brake squeal problems. This type of analysis provides areas of stability versus instability for driven parameters, thereby making it possible to define design criteria. Nevertheless, this technique does not permit obtaining the vibrating state of the brake system and nonlinear methods have to be employed. Temporal integration is a well-known method for computing the dynamic solution but as it is time consuming, nonlinear methods such as the Harmonic Balance Method (HBM) are preferred. This paper presents a novel nonlinear method called the Constrained Harmonic Balance Method (CHBM) that works for nonlinear systems subject to flutter instability. An additional constraint-based condition is proposed that omits the static equilibrium point (i.e. the trivial static solution of the nonlinear problem that would be obtained by applying the classical HBM) and therefore focuses on predicting both the Fourier coefficients and the fundamental frequency of the stationary nonlinear system.The effectiveness of the proposed nonlinear approach is illustrated by an analysis of disc brake squeal. The brake system under consideration is a reduced finite element model of a pad and a disc. Both stability and nonlinear analyses are performed and the results are compared with a classical variable order solver integration algorithm.Therefore, the objectives of the following paper are to present not only an extension of the HBM (CHBM) but also to demonstrate an application to the specific problem of disc brake squeal with extensively parametric studies that investigate the effects of the friction coefficient, piston pressure, nonlinear stiffness and structural damping.     

A numerical study on stick-slip motion of a brake pad in steady sliding

A numerical model for an elastic brake pad sliding under constant load and with constant velocity over a rigid surface is investigated by finite element analysis. The geometry is taken to be two-dimensional, the contact is assumed to follow the laws of continuum mechanics and temporal and spatial resolution are such that dynamical effects localized at the interface are resolved. It turns out that at the contact interface localized slip events occur either in the form of long-lasting slip pulses, or in the form of brief local relaxations. Macroscopically steady sliding, macroscopic stick-slip motion or slip-separation dynamics occurs, depending on the macroscopic relative velocity. While structural oscillations of the brake pad do not seem to play a significant role during steady sliding at least one structural oscillation mode becomes synchronized with the interfacial dynamics during stick-slip or slip-separation motion. Assuming a given friction law for the interface, the macroscopically observed friction coefficient depends considerably on the underlying dynamics on the interface.     

基于车用电涡流缓速器温度场分析控制系统设计

随着车辆向大型化,高速化的发展趋势,车辆正常行驶制动能量增加,传统的摩擦制动器已经难以满足使用要求,很容易诱发一些故障。电涡流缓速器以其非接触无摩擦,响应时间短,无明显时间滞后,工作时噪声很小,能够提供车辆正常行驶85%的制动功率等优点成为新型的车辆辅助制动系统。本文采用ANSYS软件实现电涡流缓速器转子盘的二维温度场分析,对不同宽度的转筒式电涡流缓速器的温度分布进行数据采集,建立转筒式电涡流缓速器转筒的二维模型,采用虚拟边界法进行简化处理,然后根据系统不同的载荷和约束条件进行温度场控制系统建模。最后本文做了大量的仿真实验,模拟了依据不同的制动力矩,不同的磁路结构以及转子盘温升来分析对汽车制动性的影响。     

Feasibility of controlling speed-dependent low-frequency brake vibration amplification by modulating actuation pressure

In this article, a feasibility study of controlling the low frequency torque response of a disc brake system with modulated actuation pressure (in the open loop mode) is conducted. First, a quasi-linear model of the torsional system is introduced, and analytical solutions are proposed to incorporate the modulation effect. Tractable expressions for three different modulation schemes are obtained, and conditions that would lead to a reduction in the oscillatory amplitudes are identified. Second, these conditions are evaluated with a numerical model of the torsional system with clearance nonlinearity, and analytical solutions are verified in terms of the trends observed. Finally, a laboratory experiment with a solenoid valve is built to modulate actuation pressure with a constant duty cycle, and time–frequency domain data are acquired. Measurements are utilized to assess analytical observations, and all methods show that the speed-dependent brake torque amplitudes can be altered with an appropriate modulation of actuation pressure.     

EXPERIMENTAL ACTIVE CONTROL OF AUTOMOTIVE DISC BRAKE ROTOR SQUEAL USING DITHER

This paper presents an experimental investigation into the application of “dither” control for the active control and suppression of automobile disc brake squeal. Dither control is characterized by the application of a control effort at a frequency higher than the disturbance to be controlled. In the particular system considered here, a vibro-acoustic analysis of a disc brake system during squeal determined the acoustic squeal signature to be emanating from the brake rotor. This squeal was eliminated, and could even be prevented from occurring, through the application of a harmonic force with a frequency higher than the squeal frequency. The harmonic force was generated by a stack of piezoelectric elements placed within the brake's caliper piston. The harmonic force represented a small variation about the mean clamping force exerted by the brake upon the rotor. The high-frequency vibration in the brake system due to the action of the control system was not heard if an ultrasonic control frequency was used. More importantly, the active control system is shown to be able to prevent squeal from even occurring. This gives rise to a possible active control system integrated into the brake system of automobiles to prevent squeal.     

LINING-DEFORMATION-INDUCED MODAL COUPLING AS SQUEAL GENERATOR IN A DISTRIBUTED PARAMETER DISC BRAKE MODEL

A distributed-parameter model of a disc brake is developed, which is used for simulation of friction-induced vibrations in the form of high-frequency squeal. The effect of different squeal generation mechanisms is investigated. The comparison of measured and calculated frequencies shows a good agreement and this study indicates that lining-deformation-induced modal coupling can act as a squeal generator in disc brakes.     

双层耦合非对称反应扩散系统中的超点阵斑图

通过线性耦合Brusselator模型和Lengyel-Epstein模型,数值研究了双层耦合非对称反应扩散系统中图灵模之间的相互作用以及斑图的形成机理.模拟结果表明,合适的波数比以及相同的对称性是两个图灵模之间达到空间共振的必要条件,而耦合强度则直接影响了图灵斑图的振幅大小.为了保证对称性相同,两个图灵模的本征值高度要位于一定的范围内.只有失稳模为长波模时,才能对另一个图灵模产生调制作用,并形成多尺度时空斑图.随着波数比的增加,短波模子系统依次经历黑眼斑图、白眼斑图以及时序振荡六边形斑图的转变.研究表明失稳图灵模与处于短波不稳定区域的高阶谐波模之间的共振是产生时序振荡六边形的主要原因.     

Dynamic photoelastic studies of wave propagation in granular media

The optical method of dynamic photoelasticity is used to visualize the load transfer profiles due to explosive loading in granular aggregates. The granular media are simulated by using arrays of disks fabricated from a brittle polyester material—Homalite 100. Attention is focused on the effect of microstructure or the geometrical packing of the grains on the wave propagation phenomena. The experimental data are analyzed to obtain the stress wave attenuation, wave velocities and contact stresses as a function of time along various directions in the assembly of grains. Dynamic load transfer functions are developed to predict dynamic contact loads in any systematic or random assembly of grains for any given loading. The predicted results are compared with the experimental data. The effect of local inhomogeneities on the wave propagation phenomena is also shown.