The need for more efficient and renewable means of transport makes the development of hybrid electric vehicles (HEVs) an important topic for both automobile manufacturers and academic researchers. Noise, vibration, and harshness (NVH) of a vehicle are important factors for vehicle users and essential for successful commercialization of this vehicle type. This paper is a compact state-of-the-art review of both NVH characteristics and relevant suppression methods for HEVs. The NVH-related problems are categorized into three categories: engine, powertrain, motor-related. A detailed overview of each category/problem-type is provided, the NVH-suppression methods for different types of HEVs are introduced, and their respective advantages discussed. In addition, emerging developments and ideas for future improvements are summarized. As a result, the paper should be particularly helpful for researchers, who are interested in the development of high-performance HEVs that can provide both substantially improved ride-comfort and reduced energy-consumption.

Noise and vibration suppression in hybrid electric vehicles: State of the art and challenges

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

The brake discs are subjected to thermal load due to sliding by the brake pad and fluctuating loads because of the braking load. This combined loading problem requires simulation using coupled thermo-mechanical analysis for design evaluation. This work presents a combined thermal and mechanical finite element analysis and evolutionary optimization-based novel approach for estimating the optimal design parameters of the ventilated brake disc. Five parameters controlling the design: Inboard plate thickness, outboard plate thickness, vane height, effective offset, and center hole radius were considered, and simulation runs were planned. 27 brake disc designs with design parameters as recommended by the Taguchi method (L27) were modeled using SOLIDWORKS, and the FEA simulation runs were carried out using ANSYS thermal & structural analysis tool. The fatigue life results were analyzed using a 3D surface plot for the effect of the design parameters on the response, contour plots for the determination of maximum response, and statistical regression analysis for model interpretation and predictive modeling. Finally, the two most accurate and widely used evolutionary optimization algorithms: genetic algorithm (GA) and particle swarm optimization (PSO) were applied to determine the optimal design parameters for the ventilated brake disc. The brake disc of design parameters predicted by GA and (PSO), gives 12.74% higher fatigue life compared to parametric analysis. These results have shown that the developed approach can be utilized effectively and reliably for solving, design ventilated brake disc problem in the industry.

Thermo-mechanical coupled analysis based design of ventilated brake disc using genetic algorithm and particle swarm optimization

Introduction.- Oscillatory Processes and Vibration.- Acoustic Radiation, Sound Waves and Fields.- Methods of Analysis of Noise and Vibration Signals.- Friction-Excited Self-Oscillations.- Noise and Vibration in Nonstationary Friction Processes.- Materials Science Approaches to Abating Noise and Vibration in Nonstationary Friction Processes.- Physiological Aspects of Human Exposure to Noise and Vibration.- Conclusions.

Noise and Vibration in Friction Systems

Brake discs are crucial part of any automobile, since they provide frictional effect for braking. They should be reliable and have long functional life. In this regard, both the fatigue life of the brake disc and its ability to resist axial deflection is important. In this research, a finite element model for a ventilated brake disc is developed to numerically simulate the fatigue life and axial deflection. The effective performance of the brake disc is analysed using a two-level full factorial design based on five different design parameters, namely inboard plate thickness, outboard plate thickness, vane height, effective offset and centre hole radius. To analyse and compare the various design parameter combinations, multi-criteria decision-making (MCDM) is used. A comprehensive comparative study for determination of design parameters is carried out by using four different MCDM methods. It is found that the optimal predictions of the four MCDMs used in the study have a high correlation. Furthermore, based on the research, a higher-level setting of all the five design variables is found to be most suitable. However, all the other four design variables except inboard plate thickness are found to have a low influence on the multi-criteria brake performance.

Finite Element Analysis and Multi-criteria Decision-Making (MCDM)-Based Optimal Design Parameter Selection of Solid Ventilated Brake Disc

The brake system of a passenger car is a complex system composed of an assembly of mechanical parts, such as springs and rubber parts, and structures filled with gas and other liquids. In order to ...

A dynamic model for brake pedal feel analysis in passenger cars

Theoretical Modeling and FEM Analysis of the Thermo-mechanical Dynamics of Ventilated Disc Brakes

Reproducing the real behavior of brake judder in time domain is useful for brake judder reduction, but it is hard to establish a time-domain model of brake judder due to the effects of thermo-mechanical coupling. To solve this problem, a modeling method is proposed taking into account the effects of thermo-mechanical coupling before hotspot occurs. In this method, an eight-degree-of-freedom dynamics model of brake caliper assembly with multi-contact points is established, and a semi-empirical model of friction coefficient is proposed by magic formula tyre model. The input of the dynamics model is the initial disc thickness variation (DTV) and the DTV caused by uneven heating, which is calculated by a transient FE model of thermo-mechanical coupling considering initial DTV. On this basis, a simulation of brake judder is conducted and an experiment is designed to validate the method. The simulated brake pressure and brake torque without and with thermo-mechanical coupling are compared with the experiment results respectively, and it indicates that the simulated results considering thermo-mechanical coupling have a good agreement with experiment results. Brake pressure variation (BPV) and brake torque variation (BTV) increase gradually in time domain because of the effects of thermo-mechanical coupling and the increments of BPV and BTV can reach 45 % and 50 % respectively in the simulation.

/pdf/modeling-and-simulation-of-brake-judder-considering-the-1tbfd2bl9x.pdf

Lijun Zhang

Papers

A dynamic model for brake pedal feel analysis in passenger cars

Theoretical Modeling and FEM Analysis of the Thermo-mechanical Dynamics of Ventilated Disc Brakes

Modeling and simulation of brake judder considering the effects of thermo-mechanical coupling

Vibration Analysis of Series-parallel Hybrid Powertrain System under Typical Working Condition and Modes

Influences of Pad Backplate on Thermo-Mechnical Coupling in Disc Brake