Abstract
Brake squeal noise has been under investigation by automotive manufacturers for decades due to consistent customer complaints and high warranty costs. J.D. Power surveys consistently show brake noise as being one of the most critical vehicle quality measurements. Furthermore, the development of methods to predict noise occurrence during the design of a brake system has been the target of many researchers in recent years. This paper summarizes the application of complex eigenvalue analysis in a finite element model of a commercial brake system. The effect of the operational parameters (friction coefficient, braking pressure and brake temperature) and wear on the dynamic stability of the brake system is examined. After identifying unstable frequencies and the behavior of the brake system under different conditions, the performance of some control methods are tested. Changes in material properties and the application of brake noise insulators are presented and their effects discussed. The results show that the effect of brake temperature changes the coupling mechanisms between rotor and pad, which in some cases can be useful in order to reduce the instabilities and generated noise. Wear is an operational condition that has an strong effect on the system instability, since stiffness properties of brake pads are influenced by the changes on geometry and on the friction material, leading to high-frequency noise generation when the system is in the end of its lifetime. Application of brake insulators requires a detailed investigation of the system since, for some cases, an increase on the system damping does not balance changes on stiffness, leading the system to instability and noise.
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