Several state of the art papers and even books on brake vibration and/or noise have been presented in the literature. Many of them have analytically and sharply accounted for the impressive amount of research undertaken on this topic. This state of the art review focuses on the still-open questions that appear crucial from the perspective of a leading brake manufacturer. The paper deals with the phenomena of brake vibration and/or noise, the experimental and theoretical methods for studying such phenomena, and the actions that are identified to be necessary to definitely solve the addressed problem. Key topics are the modelling of friction, the modelling of the dynamics of the brake as a non-linear system subjected to deterministic or random (parametric) excitation, the proper modelling of the contact between the disc and the pad, and the experimental validation of the mathematical models.

Brake comfort – a review

Disc brake system is one of the most critical components in a vehicle, which is always exposed to nonlinear transient thermoelastic conditions. Optimal design of a brake system to suit the heat transfer, weight and packing requirements is an ongoing challenge. Substantial researches have been carried out and are underway, in order to address the diverse issues related to thermal, mechanical and structural performances of automobile disc brakes. With the extensive application of numerical tools and techniques, the analyses involved became easier and effective. The present article provides an exhaustive review of the numerical and experimental studies reported so far, on the analysis and design of solid and ventilated disc brakes. The directions for future works are also described. The review reveals that, there is enough scope for extended research for realizing optimal design of disc brake system by truly emulating all the relevant practical situations.

Thermo-Mechanical and Structural Performances of Automobile Disc Brakes: A Review of Numerical and Experimental Studies

https://epublications.marquette.edu/cgi/viewcontent.cgi?article=1245&context=mechengin_fac

Crack propagation and microstructural transformation on the friction surface of a high-speed railway brake disc

Squeal is a noise phenomenon occurring in the last stage of automobile braking with a high-frequency sound. It is very difficult to express the phenomenon using a mathematical model, since the origin of squeal noise is physically complex. However, the possibility of squeal generation can be predicted by solving the vibration equation of the self-excited system using the complex eigenvalue analysis method. The results of the method are expressed as the magnitude of the unstable mode, and the generation of squeal noise can be prevented by reducing the magnitude of the unstable mode of the brake system. The objective of this research is to determine the optimal design process focused on the calliper housing shape to suppress squeal noise generation by reducing the system instability. The objective function is set to minimize the real part of the complex eigenvalue, i.e. the instability index. In the optimization design process, the design variable for topology optimization is established by focusing ...

Optimal shape design of a brake calliper for squeal noise reduction considering system instability

The aim of this study is to investigate the braking 
performance of the UTeM Eco-Car disc brake system. The disc 
brake system utilized a single cross-drilled rotor with fixed calliper design. The brake system performance in term of its thermal property was determined in transient condition using ABAQUS CAE finite element analysis software. Results from the thermal analysis showed that the maximum temperature generated at the brake disc surface was 119.2 C, which is within the allowable service temperature of the disc material. This indicates that the UTeM Eco-Car disc brake system is able to perform safely as per design requirement.

http://www.ijens.org/Vol_11_I_06/114305-06-8989-IJET-IJENS.pdf

Performance Investigation of the UTeM Eco-Car Disc Brake System

The thermal distortion induced by thermoelastic instability (TEI) results in hot spots on the surface of the brake disc. This can incur low-frequency vibration known as judder. In pad-induced squeal noise, mode coupling occurs owing to the variation in the friction coefficient between the disc and pad, inducing high-frequency noise. Through a coupled analysis of hot spots and squeal phenomena, an optimum disc and pad design can be designed for higher thermal and mechanical performance. In this study, numerical and experimental analyses are performed in accordance with disc thickness, pressurization type of caliper, and lining arc length, considering thermal and mechanical instability simultaneously. Thermal deformation and pressure distribution are calculated using a finite element analysis (FEA). For evaluating TEI performance, experiments are performed using a chassis dynamometer and a high-speed infrared camera, and the results are correlated with FEA results. A complex eigenvalue analysis is conducted to evaluate mechanical instability using an FEA. Modal testing and simulations are conducted to correlate a real model and an FE model, and the corrected simulation results are applied for a complex eigenvalue problem to analyse coupled modes according to rotor and pad shapes. The results on disc brake performances considering the disc and pad design are discussed in terms of hot spots and squeal problems.

C.-D. Cho

Papers

A study of thermal and mechanical behaviour for the optimal design of automotive disc brakes