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Research Papers

Conceptual Design Method for Reducing Brake Squeal in Disk Brake Systems Considering Unpredictable Usage Factors

[+] Author and Article Information
Toru Matsushima

Chassis System Development Division 2, Higashifuji Technical Center, Toyota Motor Corporation, 1200 Misyuku, Susono City, Shizuoka 410-1193, Japantoru@matsu.tec.toyota.co.jp

Kazuhiro Izui

Shinji Nishiwaki

Department of Mechanical Engineering and Science,  Kyoto University, Yoshida-Honmachi, Sakyo-ku, Kyoto City, Kyoto 606-8501, Japanshinji@prec.kyoto-u.ac.jp

J. Mech. Des 134(6), 061008 (Apr 27, 2012) (14 pages) doi:10.1115/1.4006326 History: Received September 30, 2011; Revised February 29, 2012; Published April 27, 2012; Online April 27, 2012

Minimizing brake squeal is one of the most important issues in the development of high performance braking systems. Furthermore, brake squeal occurs due to the changes in unpredictable factors such as the friction coefficient, contact stiffness, and pressure distribution along the contact surfaces of the brake disk and brake pads. This paper proposes a conceptual design method for disk brake systems that specifically aims to reduce the occurrence of low frequency brake squeal at frequencies below 5 kHz by appropriately modifying the shapes of brake system components to obtain designs that are robust against changes in the above unpredictable factors. A design example is provided and the validity of the obtained optimal solutions is then verified through real-world experiments. The proposed optimization method can provide useful design information at the conceptual design stage during the development of robust disk brake systems that maximize the performance while minimizing the occurrence of brake squeal despite the presence of unpredictable usage factors.

Copyright © 2012 by American Society of Mechanical Engineers
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References

Figures

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Figure 1

Experimental system to analyze the disk, caliper, and pad vibration modes during squeal occurrence

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Figure 2

Vibration modes of the disk, caliper, and brake pad during squeal occurrence

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Figure 3

Simplified brake squeal simulation model

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Figure 4

Nonuniform contact pressure distributions

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Figure 5

Coordinate system and disk dimensions

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Figure 6

Deformation due to applied friction force

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Figure 7

Relation between real and imaginary parts of complex eigen-values and friction coefficient

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Figure 8

Brake disk and pads vibration mode when brake squeal occurs

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Figure 9

Relation between real and imaginary parts of complex eigen-values and contact stiffness

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Figure 10

Experimental results to confirm the numerical analysis

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Figure 11

Relation between real and imaginary parts of complex eigen-values and uncontrollable factors μp

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Figure 12

Brake disk and pads vibration modes

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Figure 13

Relation between real parts of complex eigen-values and uncontrollable factors k¯pi and ηi

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Figure 14

Maximum value of real part of eigen-value according to central angle of pad friction surface

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Figure 15

Squeal evaluation result

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Figure 16

Squeal occurrence rate according to central angle of pad friction surface

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Figure 17

Maximum value of real part of eigen-value for optimal design

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