Finite element parametric study of the influence of material properties and structural modifications on disc brake noise phenomena

Abstract

Noise pollution is a growing environmental concern in urban areas. Road traffic is the most dominant source of environmental noise with an estimated 125 million peopleaffected by noise levels greater than 55 decibels (dB) Lden (day-evening-night level), including more than 37 million exposed to noise levels above 65 dB Lden. The vehicle components most involved in noise production and most exposed to vibration are tires, motor, outer panels of the car body, the brakes, electronic components, equipment in the inner part of the car. In the last few years, brake noise and vibration has become one of the key issues for the rating of vehicle brake systems in the automotive industry. All methods for brake noise reduction can be sorted into three categories: (1) modification of the structures of the brake parts, e.g. geometry and shape of brake components; (2) modification of the materials of some of the brake parts, e.g., the use of non-negative friction coefficient (vs. velocity characteristics) lining materials; and (3) modification of the vibration characteristics. A parametric study is carried out to study effect of changing material properties and structural modification on brake noise generations. Optimization of disc brake is performed in ANSYS software package. Application of virtual experiments in the development of products allows us savings in the production and elimination of defects.