Modeling, sensitivity analysis, and design optimization of automotive brakes for squeal reduction

Jinchun Huang, Purdue University


A numerical modeling approach is developed for an automotive drum brake system for squeal prediction, a sensitivity analysis is presented to analyze the influences of parameters on system stability, and structural optimization is performed to find the optimal solution for squeal reduction. The brake system model is based on the component modal information, which is found by Finite Element Analysis. The component models of the drum and the shoes are coupled through the shoe lining material which provides normal and frictional coupling. Both the frequency separation between two system modes due to static coupling and their associated mode shapes play an important role in mode merging. A modal expansion method is developed to calculate eigenvalue and eigenvector sensitivities. Different types of mode couplings and their relationships with squeal are discussed. The modes showing curve veering towards are very likely to merge to cause squeal if there is sufficient friction coupling. A reduced-order characteristic equation method based on the statically coupled system eigenvalues and their derivatives is presented to estimate the critical value of friction coefficient. The significance of this method is that the sensitivity of system stability with respect to design parameters can be performed directly. Optimization of lining shape is conducted by using the Genetic Algorithm. Sizing and shape optimization of other brake components is conducted with Response Surface Methodology.




Krousgrill, Purdue University.

Subject Area

Mechanical engineering|Automotive materials

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