Design And Analysis Of Disc Brake For Low Brake Squeal

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International Journal of Latest Technology in Engineering, Management & Applied Science (IJLTEMAS)Volume VII, Issue VII, July 2018 ISSN 2278-2540Design and Analysis of Disc Brake for Low BrakeSquealVijay J. Dhembare1, M. B. Mandale2, Rupesh.B.Fonde31Assistant Professor, D Y Patil College of Engineering, Akurdi, Pune, Maharashtra, IndiaAssistant Professor, Rajarambapu Institute of Technology, Rajaramnagar, Maharashtra, India3M.E Student, D Y Patil Institute of Engineering and Technology Ambi, Pune, Maharashtra, India2Corresponding Author: - Vijay J. Dhembare,Abstract: Vibration induced due to friction in disc brake is atheme of major interest and related to the automotive industry.Squeal noise generated during braking action is an indication ofa complicated dynamic problem which automobile industrieshave faced for decades. For the current study, disc brake of 150cc is considered. Vibration and sound level for different speedare measured. Finite element and experimentation for modalanalysis of different element of disc brake and assembly arecarried out. In order to check that precision of the finite elementwith those of experimentation, two stages are used bothcomponent level and assembly level. Mesh sensitivity of the discbrake component is considered. FE updating is utilized to reducethe relative errors between the two measurements by tuning thematerial. Different viscoelastic materials are selected andconstrained layer damping is designed. Constrained layerdamping applied on the back side of friction pads and comparedvibration and sound level of disc brake assembly withoutconstrained layer damping with disc brake assembly havingconstrained layer. It was observed that there were reduction invibration and sound level. Nitrile rubber is most effectivematerial for constrained layer damping.Keywords: Friction-induced vibration, Brake Squeal, Viscoelasticmaterial, Constrained Layer dampingI. INTRODUCTIONThe most important safety feature of a car is the brakingsystem, which must be slowed down quickly and reliablyin different conditions. There are many types of brakingsystems that have been used since the beginning of a motorvehicle, but in principle they are all similar. The mainfunction of the brake system is to slow down the vehicle byconverting the kinetic energy of the vehicle to friction by heat,which must be efficiently and efficiently distributed aroundthe brake components. The principle of disc braking waspatented by Frederick Lanchester in 1902 at the Birminghamfactory. However, in 1957, Jaguar was not as popular until itwas introduced to the public in a way that the advantages ofracing cars could be seen. Since the early 1960s, disc brakingsystems have become more common on most passengervehicles, but some passenger cars use drum brake on the rearwheels, which are used to simplify parking brake conditionsas well as reduce costs and weight. This can be a logicalwww.ijltemas.incompromise, as front brakes do most of the braking effort.The current research has attempted to investigate the noisescaused in passenger cars, so the disc brake will be the focus ofthis work. It is an important economic and technical issue inthe automobile industry that a squeal noise is generated duringbraking. Reevaluation of customer requirements brings highcomfort to the list of the most important design elements ofthe vehicle in order to offer the public a competitive andattractive product. Akay (2002) stated that warranty claimsarising from noise, vibration and harshness (NVH) problems,such as brake sounds in North America, are only up to onebillion dollars a year. The disc brake noise loudness is mainlydue to friction-induced vibration, which causes noise at asound frequency of 1 kHz to 16 kHz due to the dynamicimbalance of the brake system. Various theories and methodshave been proposed to explain and predict the phenomenon ofbrake whining. Nevertheless, it is clear that no one canexplain all the events related to noise. It has presentedchallenging problems for researchers and engineers due to thecomplexities of multidisciplinary structures such as theoriesabout glazes, nonlinear dynamics, contact mechanics andtribology. Over the last few decades, a significant amount ofresearch has been done by many researchers on the possibilityof lifting the brakes to improve vehicle comfort, comfort, andoverall environmental noise. Very good progress has beenmade and a number of solutions have been proposed, such asthe addition of damping shims and shifting of modalconnections. Despite this effort, squeal in the audiblefrequency range is still common. For this reason, in additionto eliminating brake leaks, a detailed and detailed study isrequired for forecasting. Sujay Hegde and B S Suresh [1]concentrated the wavering between the brake pad and discutilizing a basic 1-DOF display. In this review, stick-slipphenomenon is recreated and considered by utilizing complexnon-direct rubbing laws and contacts between a mass andmoving belt. Additionally, a parametric review is directed toconcentrate the impact of mass, spring and grindingparameters on the stick-slip impact. N.M. Kinkaid et al [2].This paper provides a comprehensive review and bibliographyof works on disc brake squeal. In an effort to make this reviewaccessible to a large audience, background sections onPage 9

International Journal of Latest Technology in Engineering, Management & Applied Science (IJLTEMAS)Volume VII, Issue VII, July 2018 ISSN 2278-2540vibrations, contact and disc brake systems are also included.Choe-Yung Teoh et al.[3] Transient analysis is carried out todetermine the brake drum response under braking conditionand the model produces squeal mode at 2026 Hz comparableto the measured squeal frequency of 1950 Hz. There arelimited combinations of the location of Centre of pressure ofthe shoes that cause squeal. The amplitude of the limit cycleof the disc brake squeal can be reduced by increasingdamping, mode frequency separation and reducing the contactstiffness. C.W. Park et al [4] The effect to brake disccorrosion on friction-induced stick-slip was studied to find thepossible causes of friction instability In humid conditions. Thefriction and wear characteristics of gray iron discs and acommercial friction material were examined using a 1/5 scaledynamometer. Use of the corroded discs result in higherfriction coefficient, oscillation amplitude of the brake torque.Disc corrosion increased the critical velocity showingtransition from steady sliding to stick-slip. This suggests arapid increase of the initial static friction coefficient as afunction of dwell time in a humid condition, which issupported by the increased hydrophilicity of the friction films.P. Liu et al [5] A new functionality of ABAQUS/Standard,which allows for a nonlinear analysis prior to a complexeigenvalue extraction in order to study the stability of brakesystems, is used to analyze disc brake squeal. An attempt ismade to investigate the effects of system parameters, such asthe hydraulic pressure, the rotational velocity of the disc, thefriction coefficient of the contact interactions between thepads and the disc, the stiffness of the disc, and the stiffness ofthe back plates of the pads, on the disc squeal. G. Lou [6]Disk brake squeal noise is mainly due to unstable frictioninduced vibration. A typical disk brake system includes twopads, a rotor, a caliper and a piston. In order to predict if adisk brake system will generate squeal, the finite elementmethod (FEM) is used to simulate the system. At the contactinterfaces between the pads and the rotor, the normaldisplacement is continuous and Coulomb’s friction law isapplied. Thus, the resulting FEM matrices of the dynamicsystem become unsymmetric, which will yield complexeigenvalues. Any complex eigenvalue with a positive real partindicates an unstable mode, which may result in squeal. Arecently developed iterative method named ABLE is used inthis paper to search for any unstable modes within a certainuser-specified frequency range. The complex eigenvaluesolver ABLE is based on an adaptive block Lanczos methodfor sparse unsymmetric matrices. Numerical examples arepresented to demonstrate the formulation and the eigenvaluesare compared to the results from the component modalsynthesis (CMS) M. Triches Jr, et al. [7] The addition of aconstrained layer material to brake pads is commonly utilizedas a means of introducing additional damping to the brakesystem. Additional damping is one way to reduce vibration atresonance, and hence, squeal noise. This work demonstratesthe use of modal analysis techniques to select brake dampersfor reducing braking squeal. The proposed methodologywww.ijltemas.inreduces significantly the insulator selection time and allowsan optimized use of the brake dynamometer to validateselected insulators. B. Ryzhik [8] The mechanism ofexcitation of friction-induced vibrations in a systemcomprising a flexible annular disk and two rigid surfaces isstudied analytically. The surfaces are pressed together, and therotating disk slides between them. It is shown that the slidingfriction in the contact between the disk and the surfaces,together with the transverse contraction in the disk material,set up a feedback between the orthogonal eigen modes of thedisk corresponding to the same eigen frequency, thusinitializing instability. The instability mechanism is illustratedby simple analytical considerations. The obtained results areconfirmed by finite-element analysis. S. Oberst et al. [9]Brake squeal has become of increasing concern to theautomotive industry but guidelines on how to confidentlypredict squeal propensity are yet to be established. While it isstandard practice to use the complex eigenvalue analysis topredict unstable vibration modes, there have been fewattempts to calculate their acoustic radiation. Here guidelinesare developed for numerical vibration and acoustic analysis ofbrake squeal using models of simplified brake systems withfriction contact by considering the selection of appropriateelements, contact and mesh; the extraction of surfacevelocities via forced response; and the calculation of theacoustic response itself. Results indicate that quadratictetrahedral elements offer the best option for meshing morerealistic geometry. Valery Pilipchuk et al. [10] Nonstationary effects in the friction-induced dynamics of a twodegree-of-freedom brake model are examined in this paper.The belt–spring–block model is designed to take into accountvariations of the normal load during the braking process. It isshown that due to the adiabatically slowing down velocity ofthe belt, the system response experiences specific qualitativetransitions that can be viewed as simple mechanical indicatorsfor the onset of squeal phenomenon .In particular, the creepslip leading to a significant widening of the spectrum of thedynamics is observed at the final phase of the process. M.Graf and G.-P. Ostermeyer [11] We show how the stability ofan oscillator sliding on a belt will change, if a dynamicfrictional with inner variable is considered instead of avelocity-dependent coefficient of friction. Unstable vibrationcan even be found in the case of a positive velocitydependency of the coefficient of friction. J.-J. Sinou et al[12]Friction-induced vibrations are a major concern in a widevariety of mechanical systems. This is especially the case inaircraft braking systems where the problem of unstablevibrations in disk brakes has been studied by a number ofresearchers. Solving potential vibration problems requiresexperimental and theoretical approaches. A non-linear modelfor the analysis of mode aircraft brake whirl is presented anddeveloped based on experimental observations. The non-linearcontact between the rotors and the stators, and mechanismsbetween components of the brake system are considered.Stability is analyzed by determining the eigenvalues of thePage 10

International Journal of Latest Technology in Engineering, Management & Applied Science (IJLTEMAS)Volume VII, Issue VII, July 2018 ISSN 2278-2540Jacobian matrix of the linearized system at the equilibriumpoint. Linear stability theory is applied in order to determinethe effect of system parameters on stability. Choe-Yung Teohet al[13]Transient analysis is carried out to determine thebrake drum response under braking condition and the modelproduces squeal mode at 2026 Hz comparable to the measuredsqueal frequency of 1950 Hz. There are limited combinationsof the location of centre of pressure of the shoes that causesqueal. The amplitude of the limit cycle of the drum brakesqueal can be reduced by increasing damping, modefrequency separation and reducing the contact stiffness. RobRedfield [14] Previous research incorporating bike framestructural dynamics and brake friction modeling has shownthat stick-slip friction is likely the cause of much of thisvibration and noise. Bicycle design parameters such as brakefriction behavior and bike component structural properties arecentral in producing and/or sustaining these vibrations. Thepredicted dynamics of these models has correlated reasonablywell with the testing of braking systems. This researchextends the modelling of previous efforts to improvecorrespondence with brake noise/vibration testing and gainfurther understanding into the contributors and possible curesof this unwanted vibration. Specifically, the extended modelincorporates torsional wheel dynamics (including rotor/hub,rim, and tire inertias, and spoke, rotor, and tire stiffnesses)into previous models. This new model allows the dynamics ofthe bike frame and wheel to couple through brakingapplication. To support and validate the modelling,motion/vibration measurements are recorded during noisybraking with a non-contact laser vibrometer in the laboratoryand with an accelerometer in field tests. Vibrationmeasurements are studied along with model predictionstoward the goal of connecting unwanted noise/vibrati

pads and the disc, the stiffness of the disc, and the stiffness of the back plates of the pads, on the disc squeal. G. Lou [6] Disk brake squeal noise is mainly due to unstable friction-induced vibration. A typical disk brake system includes two pads, a rotor, a caliper and a piston. In order to predict if a

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