Keywords: disc brake squeal, finite element analysis, FEA, modal testing, rotor design modifications, automotive braking, vehicle braking, disc brakes, vehicle noise, eigenvalue analysis, dynamic transient analysis
Modelling of automotive disc brake squeal and its reduction using rotor design modifications
This paper proposes a numerical approach to reducing disc brake squeal through rotor design modifications using the finite element method (FEM). The finite element (FE) model is validated based on the measured data extracted from experimental modal analysis for individual brake components in free-free boundary condition and brake assembly under applied pressure. The FE model is used to investigate brake squeal through two numerical approaches namely complex eigenvalue analysis and dynamic transient analysis. Experimental squeal tests are performed using a brake test rig for verification of the predicted results. It is observed that the results of both the complex eigenvalue analysis and dynamic transient analysis agree well with experimental squeal frequencies. In order to reduce brake squeal, a number of structural modifications on the disc are evaluated. The predicted results show that the squeal noise of disc brake is influenced by the natural frequency of the brake rotor and its mode shape. It is also found that a good choice of rotor geometry in the pre-design stage could help in reducing squeal noise.