Prediction and analysis of quasi-periodic solution for friction-induced vibration of an industrial brake system with the Generalized Modal Amplitude Stability Analysis

Abstract

Brake squeal is a major issue for car manufacturers as it is the reason for the return of many vehicles to customer services, representing high costs for the companies. To meet customer’s expectations, squeal must be accurately predicted during the design process. In the context of the automotive industry, squeal usually refers to friction-induced vibrations that generate noise. The main methodology employed nowadays for friction-induced vibrations prediction of industrial systems is the well-known Complex Eigenvalue Analysis (CEA) despite its limitations. The latter suffers from an under- or over-predictive aspect and the vibration amplitudes cannot be estimated. A recent approach, called the Generalised Modal Amplitude Stability Analysis (GMASA), has been developed as a complementary approach of the CEA to identify the modes involved in the nonlinear dynamic response of systems subjected to friction-induced vibrations and to approximate the quasi-periodic oscillations. The objective of this paper is to predict the nonlinear dynamic response of a full industrial automotive brake system. The GMASA is employed to predict its nonlinear dynamic response. It is demonstrated that when the CEA predicts a single unstable mode, two are actually involved in the nonlinear dynamic response. The quasi-periodic oscillations are analysed, as well as the evolution of the contact conditions at the pad/disc interface and exhibits the presence of micro-impacts.