Browse Topic: Disc brakes

Items (489)
Abstract This article takes the wet multi-disc brake used in mining Isuzu 600P as the research object, establishes a simplified three-dimensional model of its key components through SOLIDWORKS and imports it into ANSYS Workbench to establish the flow field and structure field model of the wet brake. Based on the fluid–solid coupling, the finite element simulation of the temperature field and stress field of the friction pair of the wet brake under different braking pressures, braking initial speeds, and fluid viscosities was carried out, and then the position changes of the friction pairs at high temperature hot spots and high stress points were analyzed to determine the stability of its friction performance. Finally, by comparing the temperature change curves of the same point during the braking process under different braking conditions, the validity of the finite element analysis results is verified. The results show that the flow field pressure inside the wet brake is opposite to the flow field velocity, the initial braking velocity is the most influential factor on the friction performance of the friction pair, affected by the fluid, the maximum equivalent stress of the groove between the core plates is the same as the braking force. Pressure, braking initial speed, and fluid viscosity are proportional.
Zhang, ChuanweiJin, XiaoheZhao, DaweiLiu, Jinpeng
This SAE Recommended Practice defines a clearance line for establishing dimensional compatibility between drum brakes and wheels with 19.5 inch, 22.5 inch, and 24.5 inch diameter rims. Wheels designed for use with drum brakes may not be suitable for disc brake applications. The lines provided establish the maximum envelope for brakes, including all clearances, and minimum envelope for complete wheels to allow for interchangeability. This document addresses the dimensional characteristics only, and makes no reference to the performance, operational dynamic deflections, or heat dissipation of the system. Valve clearances have not been included in the fitment lines. Bent valves may be required to clear brake drums. Disc brake applications may require additional running clearances beyond those provided by the minimum contour lines. Mounting systems as noted are referenced in SAE J694.
Truck and Bus Wheel Committee
This SAE Standard provides test procedures for air and air-over-hydraulic disc or drum brakes used for on-highway commercial vehicles over 4536 kg (10000 pounds) GVWR. This recommended practice includes the pass/fail criteria of Federal Motor Vehicle Safety Standard No. TP-121D-01.
Truck and Bus Foundation Brake Committee
This SAE Recommended Practice defines the boundary line for establishing dimensional compatibility between air disc brake calipers and 22.5 x 8.25 inch disc wheels, including bent valve stems on steel wheels and manufacturer recommended valve stems on aluminum wheels. The line establishes the minimum wheel with valve stem envelope to allow interchangeability. The line does not accommodate customer-specific wheels (such as OEM-specific stylized wheels) or customer-specific brakes. This document addresses dimensional characteristics only and makes no reference to the performance, operational dynamic deflections or heat dissipation of the system. It is up to the system integrator to ensure sufficient clearance exists between the caliper, wheel and valve stem to provide safe operating conditions. Mounting systems as noted are referenced in SAE J694.
Truck and Bus Wheel Committee
This Recommended Practice is derived from OEM and tier-1 laboratory tests and applies to two-axle multipurpose passenger vehicles, or trucks with a GVWR above 4536 kg (10 000 pounds) equipped with hydraulic disc or drum service brakes. Before conducting testing for a specific brake sizes or under specific test conditions, review, agree upon, and document with the test requestor any deviations from the test procedure. Also, the applicable criteria for the final test results and wear rates deemed as significantly different require definition, assessment, and proper documentation; especially as this will determine whether or not Method B testing is needed. This Recommended Practice does not evaluate or quantify other brake system characteristics such as performance, noise, judder, ABS performance, or braking under extreme temperatures or speeds. Minimum performance requirements are not part of this recommended practice. Consistency and margin of pass/fail of the minimum requirements related to wear rates and wear behavior can be assessed as part of the project in coordination with the test requestor. NOTE: This Recommended Practice uses the unit conversion and rounding techniques from the NIST Special Publication 811. This to ensure the use of standard conversion factors and to determine the appropriate number of significant digits to ensure the Rounding Error (RE) of the converted unit is smaller than or similar to the RE of the original English or Imperial unit.
Truck and Bus Hydraulic Brake Committee
Model-Based Brake Disc Temperature Prediction on High Speed Testing Mode and Circuit2020-01-02144/14/2020
A brake is a mechanical device that inhibits the motion by absorbing energy from a moving system. It is used for slowing or stopping a moving vehicle, wheel, axle, or to prevent its motion, most often accomplished by friction energy. Commonly, most brakes use friction between two surfaces pressed together to convert the kinetic energy of the moving object into heat, though other methods of energy conversion may be employed. If braking is repeated or sustained in high load or high-speed conditions, the motion will be unstable and can lead to a loss of stopping power because the disc capability for braking is not enough. These phenomena are generally defined as brake fading. Brake fade is caused by an overheating brake system. This paper describes the thermal modeling and process to predict the disk temperature under a condition which causes the fade characteristics. Also, the model of disc temperature prediction developed with consideration of acceleration and deceleration from the vehicle specification by combining the full vehicle modeling with thermal disc model. The disc temperature model is a highly reliable model because it is correlated with measurement data and based on this correlated thermal model, it can be predicted the brake disc geometrical parameters according to the specification change of the vehicles in the concept stage before the prototype development.
Jeong, PilYoungLee, JaekilOswald, MarioKellner, Stefan
Flow Field Experimental Study in Brake Discs with Aerodynamic Ventilation Columns06-13-01-00042/27/2020
This work presents a new design of ventilation pillars in ventilated brake discs. The use of National Advisory Committee for Aeronautics (NACA) aerodynamic profiles is proposed. Of the references consulted, there is no standard or procedure that indicates how the pillars should be installed in the ventilated discs. Therefore, it is proposed using the Kaplan’s error triangles theory of turbo hydraulic machinery to have a geometrically orderly way of placing the NACA 66-209 profiles from the suction diameter to the discharge diameter. To validate this new design, a 1:1 scale acrylic disc model was constructed, and tests were conducted in water using the particle tracking velocimetry technique to characterize the water model. The water experiment was performed at test speeds of 35, 41, 48, and 54 rpm. From the experiment in water, it is possible to visualize the flow field from the suction diameter to the model discharge diameter and scale the results to the prototype in air. Being 54 rpm in water equivalent to N = 1020 rpm in air, the radial velocity is 15.4% higher than a straight vanes disc. In addition, comparing the mass flow at the point of maximum speed, it is observed that the results obtained in this work are 40.21%, 65.49%, and 98.11% higher than those obtained by other works. Finally, the error of the accumulated experimental bias is extremely low, where the maximum error did not reach 1.17%. For this reason, it can be ensured that both the measurements made as well as the results obtained are highly reliable.
Rivera López, Jesús EduardoGutiérrez Paredes, Guadalupe JulianaQuintero Orozco, AbnerTamayo Meza, Pedro AlejandroOrozco Durán, Gabriela EsmeraldaArciniega Martínez, José Luis
Influence of Pads and Brake Disc wear on Brake Squeal Noise2019-36-00051/13/2020
The present work aims to investigate the influence of wear of the pads and brake disc on the brake squeal behavior with the help of the Finite Element tool. Brake discs basically work by the pressure of the brake pads against a rotating disc. The friction between the pads and the disc causes the latter to decelerate, but it can also cause dynamic instabilities of the system giving rise to noises. Among the main noise in vehicle brake systems, there is the squeal noise, which is usually associated with the coupling of two neighboring natural modes. One possible way to identify unstable modes is by extracting complex eigenvalues from the system. An unstable mode can be identified when, in the result of the extraction of the complex eigenvalues, the real part of the eigenvalue is positive. In the present work, a brake system (disc and positioned pads and their respective materials and friction coefficients) was duly modeled and validated. The validation was done by means of a correlation between the frequency of the noises found experimentally and the frequency of the unstable modes found in the virtual model. A parametric analysis was performed simulating the wear of the disks and pads to understand the effect of the mass variations and stiffness on the instability of the system. According to the results found in the analyzes that simulate the wear, with the decrease, mainly the thickness of the brake pads, there was an increase of numbers of unstable modes, that is, the brake system is more prone to squeal generation.
dos Anjos, Marco Túlio BatistaGutiérrez, Juan Carlos HortaFerreto, Cláudio JuniorSilva, Felipe DornellasDonadon, Lázaro Valentin
Development challenges of hydraulic brakes for commercial vehicles2019-36-00131/13/2020
The automotive research and development environment is increasingly challenging and complex, full of new technologies, regulations and customized customer needs. In addition, the cargo transportation market is very dynamic and competitive, becoming complex the strategies for companies in this segment. According to Anfavea (2018), this trend, especially in large urban centers, has driven the intention to use light commercial vehicles to capillize deliveries in destinations with a high demographic concentration and traffic limited to medium and heavy vehicles. In this scenario, the demand for diversified products is increasing in order to overcome the main tradeoff: “minimizing the size of the trucks and maximize the load capacity”. It brings the number of complex projects. The brake system is greatly impacted in these developments mainly because light commercial vehicles are situated in a weight range that we can call "identity crisis" if on the one hand they need an upgrade compared to a conventional car and use the hydraulic brake on the other one need a downgrade of a medium or heavy truck that brings robustness and pneumatic brakes. The definition of the type of assistance is a determining factor, hydraulic brake; pneumatic brake or a hybrid brake (air over hydraulic). Each type has its advantages and disadvantages, which are directly related to the vehicle's application such as installation package, serviceability, service brake costs and performance and especially parking brake. This work shows the study and development of the brake system including the detailed presentation of a dry caliper, implemented as disruptive innovation technology. It also has a new concept applied to a commercial vehicle, developed in Brasil and used as footprint own knowledge for the specific needs of the market and provides a very cost-benefit commitment for the customer, yet brings the wished confidence of the parking brake function for drivers.
Vetter, Narã VieiraCarlos de Oliveira, AntonioFontes, Eduardo Henrique SouzaNogueira, FelipeFonseca, Guilherme HenriqueNuss de Souza, Luis FernandoOliveira dos Reis, Rodrigo deManenti, Vangelo Cardoso
A New Appraisal of the Thermomechanical Behaviour of a Hybrid Composite Brake Disc in a Formula Vehicle2019-28-257211/21/2019
The present work promotes a hybrid composite brake disc for thermal and structural analysis of a formula vehicle. In order to reduce the un-sprung weight without compromising the strength, hybrid composite materials were incorporated in the disc plates of the braking system. In the disk brake system, the disc is a major part of a device used for slowing or stopping the rotation of a wheel. Repetitive braking of the vehicle leads to heat generation during each braking condition. Based on the practical understanding the brake disc was remodeled with unique slotting patterns and grooves, using the selected aluminium alloy of (AA8081) with reinforcement particle of 15wt% Silicon carbide (SiC) and 3wt% Graphite (Gr) as a hybrid composite material for this proposed work. By varying slotting pattern and groove angles the transient thermal and structural analysis using ANSYS workbench on the hybrid composite disc plate of disk brake is done. The main purpose of this study is to analyse the thermomechanical behavior of composite brake disc for a formula vehicle under severe braking conditions. To ensure the braking conditions, the coupled field analysis is done on the disk brake to determine the deformation and the Von Mises stress developed in the disc for both solid disk and disk provided with multiple ventilations (slotting patterns and grooves angles) using the hybrid composite material to improve the performance of the brake disc. Hence the best suitable design of disc plate with the hybrid composite material is recommended based on the performance, strength and rigidity criteria. Also, it will be recommended for fabrication and real-time usage in formula vehicles.
Ranganathan, SoundararajanKuppuraj, SathishkumarGopal, ShanthoshChandrasakaran, Pradeep
A Predictive Tool to Evaluate Braking System Performance Using Thermo-Structural Finite Element Model06-12-03-001410/14/2019
The braking phenomenon is an aspect of vehicle stopping performance where with kinetic energy due to the speed of the vehicle is transformed into thermal energy produced by the brake disc and its pads. The heat must then be dissipated into the surrounding structure and into the airflow around the brake system. The thermal friction field during the braking phase between the disc and the brake pads can lead to excessive temperatures. In our work, we presented numerical modeling using ANSYS software adapted in the finite element method (FEM), to follow the evolution of the global temperatures for the two types of brake discs, full and ventilated disc during braking scenario. Also, numerical simulation of the transient thermal analysis and the static structural analysis were performed here sequentially, with coupled thermo-structural method. Numerical procedure of calculation relies on important steps such that Computational Fluid Dynamics (CFD) and thermal analysis have been well illustrated in three-dimensional form (3D), showing the effects of heat distribution over the brake disc. This CFD analysis helped us in the calculation of the values of the thermal coefficients (h) that have been exploited in 3D transient evolution of the brake disc temperatures. Three different brake disc materials were tested, and comparative analysis of the results was conducted in order to derive the one with the best thermal behavior. Finally, the resolution of the coupled thermomechanical model allows us to visualize other important results of this research such as the deformations and the equivalent Von Mises stresses of the disc, as well as the contact pressure of the brake pads. Following our analysis and results, we derive several conclusions. The choice allowed us to deliver the rotor design excellence to ensure and guarantee the good braking performance of the vehicles.
Belhocine, AliWan Omar, Wan Zaidi
The Improvement Brake’s Qualities of Vehicle by Developing the Method of the Choosing Frictional Pairs of the Brakes Mechanisms2019-01-21459/15/2019
One of the reasons for the large number of road accidents on highways in Ukraine [1] is the instability of the braking properties due to the unstable characteristics of the brake mechanisms’ friction pairs. The manufacturer produces new automobiles with installed brake pairs (brake pads and their counter bodies), which have passed long-term tests for the stability of the friction coefficient and braking forces distribution of between the axles. This ensures the compatibility of the friction pairs characteristics for front and rear brake mechanisms according to the criteria of heat resistance. During operation, instead of worn-out brake pads, brake discs and drums, drivers can purchase new ones, manufactured as spare parts. However, in the well-known literature there are no methods that allow to check the compatibility of the friction pairs characteristics for front and rear brake mechanisms according to the criteria of heat resistance. In the article a method for choosing a set of friction pairs of brake mechanisms for passenger car during operation is proposed. Assessment of the compatibility of the friction pairs characteristics for front and rear brake mechanisms was carried out according to the criteria of heat resistance.
Podrigalo, MikhailKlets, DmytroKholodov, MykhailoBogomolov, ViktorTurenko, AnatoliyMolodan, AndriiRudzinskyi, VolodymyrTarasov, YuriiMykolai, AloksaHatsko, Vasyl
Stability of Wheel Tractors during Braking2019-01-21429/15/2019
The dynamic distribution of normal reactions between the axles of the wheeled tractor has a significant impact on the stability against skidding and the wheeled tractor braking effectiveness. At the same time, the clarification of the normal reactions distribution between the axles allows to choose more rational braking forces distribution between the axles. It is shown that the best way to ensure the highest braking efficiency is the braking mode when the rear wheels of the tractor are at the blocking limit. An assessment of the expediency of installing brake mechanisms on only one axle of the tractor was made. The increase of braking efficiency of wheeled tractors with all brake wheels provided that they ensure directional stability is considered. The laws of braking forces distribution between the axles of wheel tractors for different sequence of wheels locking are determined. Using the method of partial accelerations an improved method for estimating the effect of a brake system on the stability of wheeled tractor is proposed. The criterion in the form of angular acceleration in the road plane ώz, by the value and sign of which one we can estimate the operational stability of the brake mechanisms has obtained.
Podrigalo, MikhailKholodov, MykhailoKlets, DmytroDubinin, YevhenSavchenkov, BorysKoryak, AlexanderRudzinskyi, VolodymyrViktoriia, ZadorozhniaPolianskyi, Oleksandr
Squeal Noise Improvement by High Damping & High Stiffness under Layer Material2019-01-21119/15/2019
The purpose of this research is to clarify how damping characteristics of Under Layer (hereafter “UL”) material in the brake pads (hereafter “PAD”) influences brake squeal noise performance. In this study, UL material structure and dynamic viscoelasticity, for two different types of UL formulations are investigated. In addition, PAD damping ratio and squeal noise performance for multiple UL formulations are verified. As a result, the raw material orientation is determined based on manufacturing method, and it causes the UL material’s anisotropic properties. Dynamic viscoelasticity are dependent on the direction in which they are measured. In particular, the loss modulus, which is the damping element of dynamic viscoelasticity, is higher in the direction of the raw material orientation for the high damping and high stiffness UL formulation. In addition, it was confirmed that this loss modulus in the direction of the raw material orientation is effective for bending vibration. In the verification, the study focuses on the PAD damping ratio and squeal noise performance in the 1st bending vibration of the PAD. It is clarified that the PAD damping ratio increased as the loss modulus increases, which leads to improve squeal noise. In conclusion, this research proves that the high damping and high stiffness UL material is effective for squeal noise improvement.
Nishioka, MasatoJohnson, LeanneRosalez, SeanSuzuki, Shusuke
The Normal-Load and Sliding-Speed Dependence of the Coefficient of Friction, and Wear Particle Generation Contributing to Friction: High-Copper and Copper-Free Formulations2019-01-21319/15/2019
Automotive brakes operate under varying conditions of speed and deceleration. In other words, the friction material is subjected to a wide range of normal loads and sliding speeds. One widely accepted test procedure to evaluate, compare and screen friction materials is the SAE J2522 Brake Effectiveness test, which requires full-size production brakes to be tested on an inertia brake dynamometer. For the current investigation, disc pads of two types of 10 different formulations (5 high-copper and 5 copper-free formulations) were prepared for testing on a front disc brake suitable for a pickup truck of GVW 3,200 kg. Each pad had 2 vertical slots, and one chamfer on the leading edge and also on the trailing edge of the pad. One segment of the test procedure looks at the coefficient of friction (Mu) under different brake line pressures and different sliding speeds to determine its stability or variability. In all cases, the Mu is found to be dependent on the normal load and sliding speed, contrary to the commonly called “Amontons-Coulomb’s Laws of Friction”. According to Wikipedia, Guillaume Amontons (1663 - 1705) observed that the force of friction was directly proportional to the applied load, meaning constant coefficient of friction and that the force of friction was independent of the apparent area of contact, while Charles-Augustin de Coulomb (1736 - 1806) observed that when a piece of metal was slid against wood, the coefficient of friction became very dependent on the normal load and the sliding speed and warned about the limitations of Amontons’ findings. Now one wonders how and when the expression of the so-called “Amontons-Coulomb’s Laws of Friction” surfaced as universal laws. According to analysis of the test data generated in this investigation, the average Mu is found to increase linearly with the increasing total wear rates of the disc and the 2 pads (the inboard and the outboard pads) in the case of copper-containing formulations and also in the case of copper-free formulations: each type of formulation has its own linear relationship. The average Mu is found to consist of 2 parts. One part is dependent on the total wear rates of the disc and the 2 pads while the other part, which is the Mu at zero wear, is independent of the wear rates. Also in this investigation, the disc wear rate is found to be directly proportional to the total wear rate of the 2 pads (the inboard and the outboard). As the pad wear is reported to be best described by a power function of the normal load and the sliding speed, a power function becomes applicable to the disc wear rate as the disc wear rate is proportional to the pad wear rate. So the wear dependent part of the Mu becomes a power function of the normal load and the sliding speed.
Rhee, Seong K.Sriwiboon, MeechaiTiempan, NiponKaewlob, Kritsana
Research on Constant Speed Control Strategy of Water Medium Retarders for Heavy-Duty Vehicles2019-01-13044/2/2019
Hydraulic retarders are extensively used in heavy-duty vehicles because of their advantages, such as their large braking torque and long continuous operating hours. They can reduce the vehicle velocity by converting the kinetic energy of a traveling vehicle to the thermal energy of the working fluid. The water medium retarder is a new type of hydraulic retarder with the characteristics of high power density and simple structure. It uses the engine's coolant as the working medium, and the heat is directly taken away by the vehicle cooling system. Therefore, the heavy-duty vehicle can achieve long-term continuous braking during the downhill process. One of the main functions of water medium retarder is driving downhill at a constant speed which determines whether the vehicle drives stably and safely. Therefore, studying the constant-speed control strategy during downhill driving is particularly important. In this paper, the structure and working principle of water medium retarder and the dynamic characteristic are analyzed. The dynamic models of vehicle and water medium retarder are established based on dynamic analysis during downhill process. The braking process that involves the water medium retarder is divided into three stages. Then the constant speed controller of water medium retarder which include three control algorithms is designed, respectively, PID algorithm, fuzzy algorithm and fuzzy-PID algorithm. The vehicle dynamic model and the constant speed control model of water medium retarder are established using MATLAB/SIMULINK. The simulation has been carried out and the comparative analysis of three algorithms mentioned above is conducted. The simulation results show that three controllers designed in this paper can quickly and accurately calculate the target filling ratio, fuzzy controller has better constant torque control performance, and the vehicle speed error is significantly reduced, which improves the stability of the vehicle during downhill process.
Lei, YulongSong, PengxiangFu, YaoWang, YuhaiZhang, Yuchen
Properties and Limitation of an Oxide Coated Aluminum Brake Rotor2018-01-187710/5/2018
The electrification of the powertrain and the thereto related recuperation of the electric engine saves the energy in the battery and thus reduces the thermally dissipated brake energy, which leads to lower brake rotor temperatures compared to combustion engine vehicles (ICEVs). These new conditions enable to reconsider brake disc concepts. Including lightweight design in heavy battery electric vehicles (BEVs) and the increasingly reliant corrosion resistance of brake rotors, Aluminum is a promising approach for new brake disc concepts. In the past, Aluminum brake disc concepts have already been deployed. For instance Aluminum Metal-Matrix Composite (Al-MMC) concepts in the Lotus Elise S1 and on the rear axle of the Volvo V40 [1]. The presented concept is a different approach and separates the friction system from the bulk Aluminum brake disc, achieved by coating of the friction rings. By locally reinforcing the friction rings, the good machinability and ductility of the base body is maintained and simultaneously the friction surface is sufficiently protected to resist the frictional loading during a brake application. In this work, fundamental studies on a brake dynamometer were conducted and supplemented by microstructural investigation to identify damage mechanisms and to judge the technical application of the concept.
Gulden, FlorianGramstat, SebastianStich, AntonHoppel, Heinz WernerTetzlaff, Ulrich
System Identification Method for Brake Particle Emission Measurements of Passenger Car Disc Brakes on a Dynamometer2018-01-188410/5/2018
Besides particulate emissions from engine exhausts, which are already regulated by emission standards, passenger car disc brakes are a source of particulate matter. With the current car fleet it is estimated that up to 21% of the total traffic related PM10 emissions in urban environments originate from brake wear and reduction of brake dust emissions is subject of current research. For the purpose of reducing brake dust emissions by choosing low-emission operating points of the disc brake, the knowledge of the emission behavior depending on brake pressure, wheel speed, temperature and friction history is of interest. According to the current state of research, theoretical white box modeling of the emission behavior is complicated due to the complexity of tribological contact between pad and disc. Thus experimental black box modeling is supposed to describe emission behavior. In order to minimize the influence of disturbances and therefore to improve prediction accuracy of such empirical models, system identification methods based on periodical test signals, such as brake pressure sine, are used for this application. To adopt these test signals, which are established in transfer function measurements, to the application of brake particle measurements and to develop an experimental design, system theoretical quantities, such as cutoff frequency, signal to noise ratio and hysteresis, are determined in dynamometer tests. Therefore measurements of the system’s response to step and sine test signals are analyzed. System identification is executed and the applicability of periodical test signals to brake particle measurements is proven.
Niemann, HartmutWinner, HermannAsbach, ChristofKaminski, HeinzZessinger, Marco
A New Model Describing the Formation of Heat Cracks in Brake Discs for Commercial Vehicles2018-01-188210/5/2018
During the development process of brake discs for commercial vehicles, heat cracks are a frequent problem. Since no profound model to forecast the occurrence of cracks has been presented yet, their prediction is hardly ever possible. The standardized heat crack test puts the brake disc under severe thermomechanical load and therefore forces it into cracking. In this paper, results from a series of heat crack tests on the dynamometer are presented, which provide insight into the hidden processes that accelerate or slow down the heat crack propagation in brake discs. This includes an extensive experimental setup using a thermographic camera, a set of capacitive displacement sensors, a pyrometer, and sliding thermocouples as well as a unique eddy-current heat crack detector that was developed at TU Darmstadt. Continuous monitoring of disc deformation, surface temperature, and crack propagation at high sampling rates provides the base for a new, profound causal model. The model describes a chain of effects including the qualitative and quantitative influence of the surface temperature distribution to local crack propagation rates in connection with local deformation and coning of the disc. Therefore, spatiotemporal patterns of thermal and mechanical distortions of the disc are compared to each other and to the crack pattern in time and frequency domain. The observation of local hardening effects as well as microstructural transformations in regions of high crack growth completes the model. Furthermore, relations between crack propagation and brake disc design are evaluated, which reveal the influence of the cooling channel pin configuration to the crack propagation. Finally, possible future applications of the model are shown, regarding its ability to forecast the cracking tendency of a certain brake disc design during finite element analysis as well as its integration into the development process of brake discs.
Bilgic Istoc, SamiWinner, Hermann
Performance Evaluation of Two Wheeler Brake System Using Coupled Thermo-Mechanical Simulation2018-01-189610/5/2018
Safety aspect has been a key requirement in designing braking system. However, non-safety aspect like NVH and thermal performance are gaining equal importance. High engine capacity (cc) motorcycles are prone to thermal and NVH issues as braking energies are more. Therefore, virtual validation of brake disc system by considering both dynamic and thermal load with predefined assumptions is a toughest challenge when confronted with reality boundary conditions. Thus, the paper comes in a unique way of coupling dynamic and thermal load executed between multi body dynamics (MBD) and heat transfer equation which will convey results closer to real time scenario. MBD solves motion and the dynamic influence on heat transfer is calculated using “sliding boundary condition”. A series of repeated braking condition are performed on front brake disc of motorcycle. The results obtained from the analysis shows critical temperature rise. As a consequence, disc thickness variation (DTV) due to thermal expansion are aggregated when coupled with dynamic friction. DTV will prove to be critical in concerning NVH and durability issues of brake disc. Braking conditions are numerically simulated on finite element method (FEM) using nonlinear approach and results are summarized with test data.
Sukumaran, SurajKalani, DineshSuryavanshi, YogeshKokane, GirishDeshpande, MoreshKharul, Ravindra
A Study on Trigger of Small Friction Noise in Disc Brake Squeal2018-01-187210/5/2018
Disc brake squeal is caused by flutter of dynamic unstable systems under small disturbance. Therefore the research of small disturbance is very important technical issues for disc brake squeal reduction. The experimental set-up for basic research was developed based on the actual disc brake squeal vibration mode in experiment and its theoretical analysis, which replaces actual caliper and pads to cantilever type pad-caliper. Disc brake squeal depends on the natural frequency of cantilever type pad-caliper, which occurred at 2.7 kHz, 2.0 kHz and 5.3 kHz for each cantilever length L=40 mm, 50 mm and 80 mm in each friction test. In friction tests L=40 mm and 50 mm, cantilever type pad-caliper vibrates with the 1st order bending vibration mode and disc vibrates with the 1st or 2nd order bending vibration mode. In friction test L=80 mm, cantilever type pad-caliper vibrates with the 2nd order bending vibration mode and disc vibrates with the 4th order bending vibration mode. Theoretical analysis is shown here for considering disc brake squeal and its trigger. The vibration modes in each disc brake squeal are not same, but each friction point behaviour per 1 cycle during brake squeal generation is the same oval shape. These simulation results mean the same mechanisms of dynamic energy increase. On the other hand, small friction noise occurred around 1 kHz in this friction test of cantilever length L=80 mm. Then its cantilever type pad-caliper vibrates with the 1st order bending vibration mode but disc vibration amplitude is so small. This small friction noise is considered to be self-excited vibration in friction coefficient dμ/dv<0, which depends on not only friction characteristics but also the natural frequencies of cantilever type pad-caliper and disc. As disc brake squeal is considered to be triggered by small friction noise, disc brake squeal can be reduced by reduction of small friction noise.
Nishiwaki, MasaakiYamamoto, Yukio
Experimental Investigation of Low-Frequency Vibration Patterns in Automotive Disk Brake Systems: Utilization Study for Modal Simulation Methods2018-01-15136/13/2018
Increasing demands on automotive comfort as well as diminishing vehicle noise levels draw new attention towards low-frequency vibration and noise issues of disk brake systems such as creep groan and moan. In view of this problem, the experimental investigation of relevant phenomena is within the scope of this article. The related experiments concerning two different setups have been performed at a drum driven suspension and brake test rig. Both assemblies consisted of a front axle corner including all parts of the integrated brake system. In order to gain understanding of characteristic triggering mechanisms and fundamental subsystem interactions, and moreover, to verify the suitability of modal methods for simulative evaluations of creep groan or moan, specifically elaborated Operating Deflection Shape (ODS) techniques have been applied. Via analyses of four different creep groan emergences, global stick-slip cycles between disk and pads are revealed. For two dissimilar vibrations in the typical frequency range of moan, mechanisms rather associated with dynamic instabilities are identified. Based on measurement results and further theoretical considerations, the suitability of a disk brake Complex Eigenvalue Analysis (CEA), which is a linear modal simulation method designated to efficiently evaluate disk brake squeal noise, is verified with respect to the relevant friction-induced low-frequency phenomena. Even though the disk brake CEA is inappropriate to estimate a highly non-linear behavior such as involved in all four creep groan signatures, its application for accompanying damped natural oscillations as well as for both observed moan appearances is plausible. By investigation of characteristic pad vibration patterns and speeds belonging to the disk rotation, generic parameter spaces for the utilization of modal methods on harmonic low-frequency phenomena are deduced.
Pürscher, ManuelHuemer-Kals, SeverinFischer, Peter
Output-Only Modal Analysis for System Identification before Break Squeal2018-01-15036/13/2018
Typically, squealing brakes are identified at squealing conditions for FE model validation by an operational deflection shape analysis (ODS). The deflection shapes and the squealing frequency depend strongly on various internal and external boundary conditions. If the model requires more modal information about the brake system than the ODS delivers an additional experimental modal analysis (EMA) can be conducted at standstill. In total, both analyses - ODS and EMA - cover only two distinctive operation points of the brake and do not provide further information. Plus, both are special cases since the usual brake condition should be a quiet braking process. To validate the internal and external boundary conditions of the brake system it is useful to have more operation points for model alignment. Because it is difficult to measure the excitation during such a quiet braking action only an operational modal analysis (OMA) can be used to identify the brake system at any arbitrary brake condition. In this paper, the method of OMA is transmitted from civil structures which are typically vibrating at frequencies below 5 Hz to hydraulic brake systems which squeal with 1-10 kHz. This involves several difficulties for the algorithm to be used as well as challenges for the measuring equipment due to the required analyzer settings. In the end, one particular OMA algorithm is chosen from several possibilities in frequency and time domain and is presented together with the associated identification results for one exemplary brake system.
Siegl, BenjaminBauer, Jens
Fast Prediction of Disc Brake Squeal Uncertainty Based on Perturbation Concept2018-01-06774/3/2018
It is a worldwide technical difficulty to predict brake squeal uncertainty and its propagation regularity due to key parameters’ randomcity. However, as a widely used stochastic finite element method, Monte Carlo Method costs a large amount of time in calculation. It is very important to establish a fast prediction method for brake squeal uncertainty due to key parameters. In this paper, perturbation concept was applied for disc brake squeal uncertainty prediction. Firstly, a simplified, parameterized finite element model of disc brake was established for complex eigenvalues calculation. Then sensitivity analysis of real parts and frequencies of complex eigenvalues to influence parameters was carried out based on the finite element model. A series of second order perturbation polynomial formulas were fitted from the sensitivity analysis results, which were used for calculation of uncertain complex eigenvalues. The comparison between the results of Monte Carlo method and those of Perturbation method was done from the viewpoints of samples values, statistical values, probability density histograms and probability density curves. The comparison results show that the relative error of perturbation method to Monte Carlo method is less than 5%, and the calculation time is reduced to less than 5%, too. This indicates that the established uncertainty prediction method based on perturbation ideal is a satisfied object oriented brake squeal uncertainty method, which has higher precision and higher efficiency.
Li, WenboZhang, LijunMeng, Dejian
Application Limits of the Complex Eigenvalue Analysis for Low-Frequency Vibrations of Disk Brake Systems2017-01-24949/17/2017
Complex Eigenvalue Analysis (CEA) is widely established as a mid- to high-frequency squeal simulation tool for automobile brake development. As low-frequency phenomena like creep groan or moan become increasingly important and appropriate time-domain methods are presently immature and expensive, some related questions arise: Is it reasonable to apply a CEA method for low-frequency brake vibrations? Which conditions in general have to be fulfilled to evaluate a disk brake system’s noise, vibration and harshness (NVH) behavior by the use of CEA simulation methods? Therefore, a breakdown of the mathematical CEA basis is performed and its linear, quasi-static approach is analyzed. The mode coupling type of instability, a common explanation model for squeal, is compared with the expected real world behavior of creep groan and moan phenomena. Problems of the CEA regarding the context of stick-slip vibrations, non-linear stiffness and local damping behavior of elastomer bushings and joints are discussed. Their importance for low-frequency phenomena and evolving oscillation limit cycles is evaluated, leading to the statement of an application limit for disk brake related CEA usage in Finite Element (FE) environments. Especially the linearization of frictional forces in the brake disk/pad contact is identified as an important limitation. A FE-model of a vehicle’s front corner was used for low-frequency CEA simulations and parameter studies. Experiments with a corresponding setup have been performed on a drum-driven suspension and brake test rig in order to evaluate theoretical considerations as well as vibration characteristics of creep groan and moan. Both the simulative and experimental investigations show the importance of modelling parameters, linearization methods and physical limitations for the application of CEA methods on low-frequency vibration analyses of disk brake systems.
Huemer-Kals, SeverinPürscher, ManuelFischer, Peter
Influences of Initial DTV on Thermomechnical Coupling in Disc Brake System2017-01-24929/17/2017
In this paper, the initial disc thickness variation (DTV) of a ventilated disc in automotive brake system is modeled as sinusoidal function of the second order. The transient thermomechanical coupling properties of the brake system is simulated using finite element (FE) modeling. The system models and results were verified by a thermomechanical coupling test of a disc brake conducted on a brake dynamometer. By using varied evaluation indexes such as the temperature distribution, the normal stress and the elastic deformation of disc surfaces, the influences of the initial DTV and its direction as well as its amplitude on the thermomechanical coupling characteristics were analyzed. The simulation results show that the distribution of temperature and the normal stress in circumferential direction exhibit the same sinusoidal function of the second order as the modeled initial DTV property, which is different from the thermomechanical coupling characteristics caused by disc surface initial run-out (LRO). Whereas the thermomechnical coupling property of the disc in circumferential direction exhibit the same sinusoidal function of the second order as that of the initial DTV, the distribution of the temperature, the normal stress and the elastic deformation in radial direction are found to be uniform. The changes in the magnitude of initial DTV are found to have insignificant effects on the changes in the overall thermomechnical coupling property. However, the circumferential gradients of the temperature, the normal stress, and the maximum disc distortion increase linearly with the increase of the magnitude of the initial DTV. The radial gradients of these quantities are not linear proportional to the magnitude of the initial DTV.
Meng, DejianWang, ZiyiZhang, LijunYu, Zhuoping
Study of Difference in Friction Behavior of Brake Disc Rotor with Various Surface Textures during Running-In by Using Simple Model2017-01-25119/17/2017
The most fundamental function of an automobile brake system is assuring stable braking effectiveness under various conditions. In a previous paper (2004-01-2765), the author et al. confirmed that the friction behavior of disc brakes during running-in depends on both the friction materials and discs’ friction-surface textures. Various friction pairs were tested by combining discs finished with roller-burnishing and grinding and five friction materials including NAO and low-steel. Some NAO material exhibited large effects on the difference in friction behaviors between the discs’ surface textures. A disc finished with roller-burnishing needed a longer running-in period than that with grinding. In another paper (2011-01-2382), a further experiment was conducted by combining eight surface textures (finished under four turning conditions with and without additional roller-burnishing), two NAO materials, and two rotational directions. Notable phenomena were observed, e.g., the coefficients of friction had a peak at the early stage of testing and there was a difference in those at the final stage between surface textures. These behaviors were determined to be due to the contribution of aggressiveness and adhesiveness to friction by comparing the coefficients of friction and discs’ surface textures and wear. Friction behaviors at the early stage of use have become more significant since the running-in period has been extended due to the application of large discs for better braking performance and the increase in the number of hybrid and electric vehicles equipped with regenerative braking. In this study, therefore, simplified linear (2D) and areal (3D) roughness models with various surface textures were introduced, and their behaviors of wear and roughness were numerically simulated. The change in discs’ surface textures along with increasing wear depended on their initial textures. These models and simulation confirmed the effects of surface textures on friction during running-in, which were experimentally observed in the previous studies.
Okamura, Toshikazu
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