Optimal shape design of a brake calliper for squeal noise reduction considering system instability

Abstract

Squeal is a noise phenomenon occurring in the last stage of automobile braking with a high-frequency sound. It is very difficult to express the phenomenon using a mathematical model, since the origin of squeal noise is physically complex. However, the possibility of squeal generation can be predicted by solving the vibration equation of the self-excited system using the complex eigenvalue analysis method. The results of the method are expressed as the magnitude of the unstable mode, and the generation of squeal noise can be prevented by reducing the magnitude of the unstable mode of the brake system. The objective of this research is to determine the optimal design process focused on the calliper housing shape to suppress squeal noise generation by reducing the system instability. The objective function is set to minimize the real part of the complex eigenvalue, i.e. the instability index. In the optimization design process, the design variable for topology optimization is established by focusing on the finger part of the calliper housing, which transmits the braking pressure to the pad lining. To supplement the complex shape generated by the topology optimization process, parametric design variables are selected for the subsequent process. Parameters are set to adjust the housing finger stiffness and are defined by considering the topology optimization result. Finally, the asymmetric shape of the calliper housing is obtained to reduce squeal noise generation.

A universal approach to squeal analysis of the disc brakes involving various types of uncertainty

“…In the literature, the real part of an unstable eigenvalue is usually taken as an index for evaluating the quality of a brake in terms of the squeal noise. 13,32,33 It is very common to set a target value for this index. If the real parts remain smaller than the target level in different CEA runs, the brake design is considered acceptable.…”

Optimization of Brake Calipers Using Topology Optimization for Additive Manufacturing

“…Farias, et al [13] optimized a brake caliper in order to reduce both its weight and its heat transfer. On the other hand, Soh and Yoo [14] optimized the shape of a brake caliper for squeal noise reduction. Finally, Sergent, et al [15] optimized the mass of an opposed piston brake.…”

An optimization method for brake instability reduction with fuzzy-boundary interval variables

“…In traditional numerical analysis and optimization, the physical parameters of analysis model are usually regarded as deterministic values. 1 However, in real-world engineering structures, the uncertainties associated with the physical properties and boundary conditions are unavoidable due to the effects of manufacturing errors, aggressive environment factors, system complexities, and so on. Over the past few decades, the issues of uncertainty analysis and optimization have attracted more and more attention in scientific fields, such as the fields of material science, 2 structural mechanics, 3,4 and automotive engineering.…”

“…Based on the above-mentioned analyses, it is well known that there are still some important issues to be solved in the field of uncertainty analysis and optimization or in the field of brake squeal, which can be summarized as follows: (1) to handle mixed fuzzy and interval uncertainties, the previous analysis method 38 is mainly based on Monte Carlo simulation (MCS), which seems not very efficient, especially when it is incorporated into a reliability-based optimization; (2) the structure response involving fuzzy-boundary interval uncertainty has been analyzed in Lu¨et al, 38 but the corresponding reliability analysis and optimization design have not been explored; (3) the reliability analysis and optimization design of brake squeal involving interval and fuzzy uncertainties are of great significance, but they have been rarely investigated at present.…”