Thermal Deformation Analysis of Automotive Disc Brake Squeal
Automotive disc brake squeal has been a major concern in warranty issues and a challenging problem for many years. A variety of tools have been developed which include both experimental studies and numerical modelling technique to tackle the problem. The aim of this project is to develop a val...
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| Format: | Thesis |
| Published: |
2009
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| Online Access: | http://eprints.utem.edu.my/4132/ http://eprints.utem.edu.my/4132/1/Thermal_Deformation_Analysis_of_Automotive_Disc_Brake_Squeal.pdf |
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| Summary: | Automotive disc brake squeal has been a major concern in warranty issues and a
challenging problem for many years. A variety of tools have been developed which
include both experimental studies and numerical modelling technique to tackle the
problem. The aim of this project is to develop a validated thermo-mechanical finite
element model considering both the mechanical structural compliance and thermal
effects in the dynamic instability of a disc brake system leading to squeal. A key issue
in the process is to investigate the structural deformation of the brake components due
to the combined effect of thermal expansion and contact loading between pad and disc
when subjected to temperature change during a typical braking cycle. A new
methodology is introduced whereby a fully coupled transient thermo-mechanical
analysis is carried out to provide the temperature and contact distributions within the
brake before executing an instability analysis using the complex eigenvalue method. A
case study is carried out based on a typical passenger car brake as it undergoes a partial
simulation of the SAE J2521 drag braking noise test. The actuation pressure, coefficient
of friction and vehicle travelling speed are all considered to derive the temperature
dependent contact pressure distributions making allowance for the “rotating heat
source” effect. An experimental investigation using a brake dynamometer is also carried
out to measuring the squealing noise and thermal deformation which leads to a
validation of the results predicted by the numerical modelling. It is demonstrated that
the fully coupled thermo-mechanical FE model enhances understanding of the time
dependent non-linear contact behaviour at the friction interface. This, in turn,
demonstrates the fugitive nature of brake squeal through the system eigenvalues that
appear and disappear as a function of temperature throughout the braking period.
Parametric studies on the geometrical effect and materials of brake components
determine the contribution of each of these factors to brake squeal. The approach
therefore can be use as a predictive tool to evaluate disc brake squeal using finite
element method. |
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