Chaos in brake squeal noise

Brake squeal has become an increasing concern to the automotive industry because of warranty costs and the requirement for continued interior vehicle noise reduction. Most research has been directed to either analytical and experimental studies of brake squeal mechanisms or the prediction of brake squeal propensity using finite element methods. By comparison, there is a lack of systematic analysis of brake squeal data obtained from a noise dynamometer. It is well known that brake squeal is a nonlinear transient phenomenon and a number of studies using analytical and experimental models of brake systems (e.g., pin-on-disc) indicate that it could be treated as a chaotic phenomenon. Data obtained from a full brake system on a noise dynamometer were examined with nonlinear analysis techniques. The application of recurrence plots reveals chaotic structures even in noisy data from the squealing events. By separating the time series into different regimes, lower dimensional attractors are isolated and quantified by dynamic invariants such as correlation dimension estimates or Lyapunov exponents. Further analysis of the recurrence plot of squealing events by means of recurrence quantification analysis measures reveals different regimes of laminar and random behaviour, periodicity and chaos-forming recurrent transitions. These results help to classify brake squeal mechanisms and to enhance understanding of friction-related noise phenomena.     

Suppression of brake squeal noise applying finite element brake and pad model enhanced by spectral-based assurance criteria

An enhanced dynamic finite element (FE) model with friction coupling is applied to analyze the design of disc brake pad structure for squeal noise reduction. The FE model is built-up from the individual brake component representations. Its interfacial structural connections and boundary conditions are determined by correlating to a set of measured frequency response functions using a spectral-based assurance criterion. The proposed friction coupling formulation produces an asymmetric system stiffness matrix that yields a set of complex conjugate eigenvalues. The analysis shows that eigenvalues possessing positive real parts tend to produce unstable modes with the propensity towards the generation of squeal noise. Using a proposed lumped parameter model and eigenvalue sensitivity study, beneficial pad design changes can be identified and implemented in the detailed FE model to determine the potential improvements in the dynamic stability of the system. Also, a selected set of parametric studies is performed to evaluate numerous design concepts using the proposed dynamic FE model. The best pad design attained, which produces the least amount of squeal response, is finally validated by comparison to a set of actual vehicle test results.     

Analysis of brake squeal noise using the finite element method: A parametric study

Brake squeal noise has been under investigation by automotive manufacturers for decades due to consistent customer complaints and high warranty costs. J.D. Power surveys consistently show brake noise as being one of the most critical vehicle quality measurements. Furthermore, the development of methods to predict noise occurrence during the design of a brake system has been the target of many researchers in recent years.This paper summarizes the application of complex eigenvalue analysis in a finite element model of a commercial brake system. The effect of the operational parameters (friction coefficient, braking pressure and brake temperature) and wear on the dynamic stability of the brake system is examined. After identifying unstable frequencies and the behavior of the brake system under different conditions, the performance of some control methods are tested. Changes in material properties and the application of brake noise insulators are presented and their effects discussed.The results show that the effect of brake temperature changes the coupling mechanisms between rotor and pad, which in some cases can be useful in order to reduce the instabilities and generated noise. Wear is an operational condition that has an strong effect on the system instability, since stiffness properties of brake pads are influenced by the changes on geometry and on the friction material, leading to high-frequency noise generation when the system is in the end of its lifetime. Application of brake insulators requires a detailed investigation of the system since, for some cases, an increase on the system damping does not balance changes on stiffness, leading the system to instability and noise.     

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.     

A note on safety-relevant vibrations induced by brake squeal

Brake squeal is mostly considered as a comfort problem only but there are cases in which self-excited vibrations of the brake system not only cause an audible noise but also result in safety-relevant failures of the system. In particular this can occur if lightweight design rims having very low damping are used. Considering the special conditions of lightweight design rims, a minimal model for safety-relevant self-excited vibrations of brake systems is presented. It is shown that most of the knowledge emanated from investigations of the comfort problem can be used to understand and avoid safety-relevant failures of the brake system.     

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.     

Modelling of squeal noise attenuation of ring damped wheels

The called vibratory instability squeal that appears in narrow curve or in end of braking is today uncontrolled and produced a high pitched noise very intense and unbearable. Many systems have been developed to limit acoustic emissions and particularly the metallic ring damping solution. Attenuation can reach 20 dB depending on the wheel type (Corail, safety wheel, etc.). However, the question is why this system has a various efficiency even on similar wheels and if this solution may be optimized. The aim of this paper is to understand the attenuation mechanisms of the ring dampers. Wheel modes susceptible to squeal are highlighted and numerical models are developed in order to simulate how the acoustic attenuation occur.     

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.     

Structural optimization of an asymmetric automotive brake disc with cooling channels to avoid squeal

Brake squeal is still a major issue in the automotive industry due to comfort complaints of passengers and resulting high warranty costs. Many measures to avoid squeal have been discussed in the engineering community reaching from purely passive measures like the increase of damping, e.g. by the application of shims, to the active or semiactive suppression of squeal. While active measures can be effective but are elaborate and therefore more expensive, passive measure are less complex in most cases. This leads to the necessity to develop passive, economic and robust measures to avoid squeal. Asymmetry of the brake rotor has been proposed to achieve this goal and the resulting split of all double eigenfrequencies of the brake rotor has lately been shown to stabilize the system.     

Effectiveness of multilayer viscoelastic insulators to prevent occurrences of brake squeal: A numerical study

The purpose of this publication is to give an overview of the actual role of multi-layered viscoelastic parts, so called “shims”, to prevent squeal noises of automotive brake systems. Since shear stress is usually used to damp thin structures in their bending modes it is commonly believed to be the largest underwent by shims. To check this assumption and considering that stresses underwent by shims cannot be measured experimentally, the authors have computed them with the help of a detailed and realistic finite element model. Contrary to what shims manufacturers say, this study exhibits the fact that shims are almost uniquely solicited in their normal direction in brake systems. Secondly, the study focuses on the added damping and stiffening induced by the viscoelastic materials. In order to take into account these materials, a realistic frequency dependent viscoelastic behavior has been integrated in the simulations. Finally, the study shows certains eigenmodes for which the viscoelastic behavior of the shims reveals instabilities that would not exist without it. It is shown that this is due to coalescence phenomenon.     

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.     

A three-dimensional physical model of MRI noise based on current noise sources in a conductor

Magnetic flux noise is generated by any conductor in equilibrium with a bath as a result of random fluctuating currents. A physical model of this flux noise is proposed, based on allowable current patterns in the conductor, which we describe as natural current modes. This model gives insight into the spatial characteristics of the magnetic noise which is encountered in a variety of magnetic measurements and imaging modalities such as magnetic resonance imaging (MRI).     

Effect of noise on defect chaos in a reaction-diffusion model

The influence of noise on defect chaos due to breakup of spiral waves through Doppler and Eckhaus instabilities is investigated numerically with a modified Fitzhugh-Nagumo model. By numerical simulations we show that the noise can drastically enhance the creation and annihilation rates of topological defects. The noise-free probability distribution function for defects in this model is found not to fit with the previously reported squared-Poisson distribution. Under the influence of noise, the distributions are flattened, and can fit with the squared-Poisson or the modified-Poisson distribution. The defect lifetime and diffusive property of defects under the influence of noise are also checked in this model.     

Phototransistor noise model based on noise measurements on PNP PIN phototransistors

A noise model for phototransistors in open base configuration is presented. The model was developed from the noise measurements on four different phototransistor designs. The extracted current gains from the noise model were verified by measured current gains from Gummel measurements. Furthermore the current noise spectral density was modeled and compared with the noise measurements. A difference of less than 12 % in the current gain was achieved. In addition to the extracted current gains also the most dominant shot noise terms including their values of each phototransistor are extracted.     

A laboratory model of a spring thermal bar

A laboratory setup for thermal bar phenomenon simulation is developed and mechanisms behind the thermal bar formation and evolution are experimentally studied. The results of the model experiments are compared with the data from natural observations, and the principal feasibility of laboratory simulation of thermal bar observed in natural water basins is demonstrated.     

Excess noise for a lattice gas model of a resistor

We model a resistor by a stochastic lattice gas: Charge carriers jump randomly to neighboring lattice sites and interact by the constraint of single site occupancy. In contrast to independently moving charge carriers, the excess noise to quadratic order in the driving force for this model behaves for small frequencies as ^-1/2, |log|, ^d/2-1 for dimensionsd=1,2,3,..., respectively. We show that for this model the relationship between the excess noise and the four point current correlation function in equilibrium as proposed by Stanton and Nelkin becomes exact. This supports the view that the 1/f-noise may be related to the long time tail in the four point current correlation function.     

Growth in a restricted solid on solid model with correlated noise

We introduce correlated growth into a restricted solid on solid model (RSOS), a stochastic deposition model with a constraint on neighboring height differences. A two-dimensional lattice model is used in which particles are deposited via horizontal Levy flight steps with a step length distribution exponentf. Though RSOS is in the same universality class as ballistic deposition for uncorrelated deposition, it appears to depart from it for strong correlations. Forf=1, the short-range limit is reached and both exponents and, which describe the dependence of surface width on time and strip length, tend to 1. Forf>1 we retreat to an enhanced algorithm, searching for growth sites which become excessively rare. We find an unusual short-time dependence, but still tends to 1. The number of growth sitesG shows saturation forf<1, while forf1 we observeG/L0 as the strip lengthL increases. Finally, we test directly the relationship of noise-noise correlation strength tof, and find that a direct comparison between correlated growth models and theoretical predictions for growth with correlated noise is so far unjustified.     

A laboratory investigation of noise reduction by riblike structures on the ground

This paper investigates the use of periodically spaced edges or wells for the control of road traffic noise. The wells have uniform height and width and are placed on the ground. Physical scale modeling is used to assess the acoustic performance of these structures under laboratory conditions. It is shown that, in certain situations where the use of conventional barriers would not be appropriate, strategically designed riblike structures can provide insertion losses of typically 10-15 dB. The findings are explained in terms of acoustic scattering with the approaches used in the study of resonators and diffraction/interference gratings.