Brake systems Automotive NVH Course February 2004

Mehdi Batel

Automotive NVH

Role of Brake system in car

z

Brakes used to decelerate the vehicle, and convert the kinetic energy into heat.

1 Ek = Mc 2 2
z

Vehicle of Mass M=1000kg, at speed 72km/h will have Ec = 200 kJ. This energy need to be totally disspated for the vehicle to stop. Transformation of the energy onto heat: 200000 = 47 kcalories 4,18
Automotive NVH

Brake system description

z

Hydraulic Pressure applied at the back of the piston and presses the pad onto the disk (typically 1 or 2 pistons) z Creation of a non-conservative friction force F f = FN

Automotive NVH

Brake Noise & Vibration

z z z z z

Noise & Vibration problems happening at a wide ranges of frequencies - great influence from temp, speed, pressure. Transition from kinetic energy into thermal energy can be oscillatory, creating emission of sound. Friction forces induce a slip-stick effect. Instability is created from increased friction Noise can be generated by a single oa combination of energy sources (ex: modal coupling between rotor and caliper)
Moan Creep groan Grunt Groan DTV Judder Squeal Squeak Wire Brush Low Frequency resonance of brake & suspension Slip-Stick motion at low speed End of stop grunt (low frequency resonance) Vibration of Brake, suspension and chassis Vibration due to Torque Variation (disk thickness variation) Torque variations due to hot spots on the disc mid to high frequency: clear tone sound High frequency tone sound Multiple noises at high frequency 50 to 200 Hz 1 to 20 Hz 50 to 200 Hz 50 to 200 Hz 50 to 200 Hz 100 to 500 Hz 1 to 12 kHz 8 to 16 kHz 8 to 16 kHz

Automotive NVH

Rotor Disc: Equations of Motion for Out-of-Plane Motion

z

Circular Disk Out-of-Plane Vibration

4

2u z Equation of motion: D u + h 2 = 0 t
z z

2 1 2 1 2 = 2+ + 2 r r r 2 r
2

4 2 Eigen-equation becomes: D U h U = 0

Solution in the form: U ( r , ) = R ( r )( ) System of equations:

d 2 + k 2 = 0 2 d

d 2 R 1 dR 2 k 2 dr 2 + r dr + r2 R = 0

Automotive NVH

Solutions OP Modes
z

Solutions in the form

U ( r, ) = R ( r )( )
z z z

( ) = A cos n ( )
R ( r ) = CJ n (r ) + DI n (r ) + EYn (r ) + FK n (r )
Bessel functions

OP Bending Modes OP Twisting Modes OP Umbrella Modes

Automotive NVH

Equations of Motion for In-Plane Motion

z

Dynamically Coupled equations:

EI a2 3ur 2u 3 2 EA 2u ur 2u 2 + + A t 2 = 0 a2

EI a4
z

4ur 3u 4 3

EA u 2 ur + a 2 + ur + A t 2 = 0

Eigen-equations:

EI, EA: stiffness constants a: geometry constant

EI a4

d 2U d 3U r EA d 2U dU r 2 + A U = 0 d 2 + d + a2 d 2 d 3 d 3U d 4U r EA dU 2 U + A Ur = 0 + r 4 2 d 3 d a d

EI a4

Automotive NVH

Modes of In-Plane Motion

Solutions

U r ,n ( ) = An cos n( ) U ,n ( ) = Bn sin n( )

For mode i:
2 EI 2 n + An EA ,i a a2 An ,i = 2 2 i =1, 2

Bn ,i

( ) (n a ) (n a ) EI + EA

z z

In Plane Radial: breathing mode In Plane Circumferencial: longitudinal mode

Automotive NVH

Operating Deflection Shape at 5400 Hz dyno test

z

Extensive testing on brake dynamometers with temperature, pressure and other load conditions control

Automotive NVH

Brake pad mode shapes

z

Brake Pad mode shapes under free-free boundary conditions

B: Bending Mode T: Twisting Mode Frequency 1700 Hz 3500 Hz 4000 Hz 5900 Hz

Pad Shape Modification:eliminate couling between rotor modes and pad modes: modify the arc swept or chamfers

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Automotive NVH

Caliper Bracket Mode Shapes

z

Caliper Housing under free-free bounrary conditions z Will exhibit bending and torsional motion from 2 kHz to 6,5 kHz z Can generate low frequency squeal if bending modal coupling with rotor
Frequency
2000 Hz 2500 Hz 3200 Hz 4500 Hz 4900 Hz 6200 Hz

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Automotive NVH

System Model instability example

z z z z z

Resolution of complex eigenvalue problems Investigations of unstable modes Example of an unstable mode at 2,5kHz Large participation of the rotor mode (0,3) Modal Participation factors:
Rotor (Mode 3): 23 % Caliper Rigid Body: 24 % Pads Rigid Body: 16 % Bracket Modes: 29 % Others: 8%

Dynamic instability due to interaction between rotor and bracket modes

Source: Delphi

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Automotive NVH

Example of control
z

Brake rotor: minimize the compression motion

Design the colling vane so that they provide enough shear stiffness Maximize the nuber of vanes to facilitate air flow Place vans unevenly spaced

For in plane modes:

Increase rotor stiffness Use rotor damping (iron casting) Try to introduce assymetries

Out of plane motion

Chamfers in the brake pads Use shorter lenght pads Use pad insulators Rotor asymetry & damping

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Automotive NVH