sensitivity of brake squealing concerning scattered …...sensitivity of brake squealing concerning...
TRANSCRIPT
Sensitivity of brake squealing concerning scattered component,
joint and bearing properties
Dr. Ronaldo F. Nunes, Daimler AG, Mercedes-Benz Cars and M.Sc. Christian Büttner (Altair Engineering GmbH)
22.11.2013
Page 2
Agenda
1 Simulation, Bench and Vehicle
2 NVH - Target
3 NVH – Squealing Joints Influence
4 Summary
Dr. Nunes, Büttner - WOST
Page 3
Introduction
Introduction
Dr. Nunes, Büttner - WOST
Page 4
Vehicle
Simulation
Bench
� Quality Control regarding Brake disc Eigenfrequency, lining material, etc.
Simulation, Bench and Vehicle(Interdisciplinary Strategy: Cross Correlation Simulation, Bench and Vehicle)
Source: EuroBrake 2012Dr. Nunes, Büttner - WOST
Page 5
Notice: Factor 1 means 0.8 to 1.5 mm tolerance
Operating Points
Material
(Lininig material,
Disc, Caliper, Axle,
Shim and so on)
Geometry
Uncertain Parameters: E-Modulus, Material Density and Geometry (for example Knuckle)
Dr. Nunes, Büttner - WOST
Page 6
Robustness Analysis Combined with Optimization Strategy (120 Designs – Complex Eigenvalue Analysis)
Baseline SystemNVH –Opt.
(Current Package)
NVH - Target : Focus to find out the best
solution taking into account the
influence of uncertain parameters
Dr. Nunes, Büttner - WOST
Page 7
NVH – Squealing Joints Influence
Dr. Nunes, Büttner - WOST
Page 8Dr. Nunes, Büttner - WOST
Backingplate
Lower ArmSteering Rod
Wishbone
Hub Unit
Pistons
Friction Material
Anchor (Caliper)
Wheel Bearing
Caliper
Tension Strut
Brake Disc
Knuckle
CAD Model – Car Brake and Suspension
Page 9
Mathematical Equations
� �M λ + D λ + C] {ω} = 0
� λ = ∝ ��ω
α = Real Part
� = Imaginary Part (Squeal Frequency)
� � � ∗ �� � � ∗ � ∝���
� �� ��� ∗ ���� � ��∗ ������
Stable / Unstable – Evaluation of complex Modes
� α < 0 System is stable
� α > 0 System not stable
Dr. Nunes, Büttner - WOST
Positive α indicates a system behavior with an increasing amplitude
of the brake oscillation
Background: Brake Squeal Analysis
Complex Eigenvalue
Analysis (CEA)
Page 10
• Without Friction: Independent Eigenmodes
• Convergence of Eigenfrequencies with increasing µ
� Mode Coupling at µcrit
� Unstable System (Squealing Propensity)
Dr. Nunes, Büttner - WOST
Background: Complex Eigenvalue Analysis
Independent
Eigenmodes
µcrit
Coupling
µcrit
Page 11
� Bearings, Ball Joints and Kinematic
Description
Joints Modeling
rigid
Kinematic CouplingRubber
Stiff Spring
Kinematic Coupl.
Dr. Nunes, Büttner - WOST
Page 12
Bench Test – Noise Problem
Bench• Noise problem identified
• Deterministic FE simulation was not
able to
find the critical frequency !!
� Sensitivity Analysis
Ball Joints, Bearings stiffness
Pad and Disc stiffness/Geometry
Brake PressureS
ou
nd
Pre
ssu
reL
eve
l
Frequency
Dr. Nunes, Büttner - WOST
Page 13
� Complexe Eigenvalue Analysis investigates Stationary System
� Frequency, amplitude and temperature depending behavior not considered
in single Calculation
Dr. Nunes, Büttner - WOST
Material Behavior in CEA
Frequency
Dyn
am
ic S
tiff
ne
ss
Page 14Dr. Nunes, Büttner - WOST
Workflow: Sensitivity Analysis
FEM Process
Stable?
� Calculation
Variation of Material
and Geometry
Post Processing
Statistical Evaluation of the
Analysis
Page 15
� Dynamic Measurements Available: Ball joints and Bearings
� Sensitivity Analysis was adopted in order to identified the influence of
Joint stiffness to the noise problem
Instability
Influence
Sensitivity Analysis: Joints Influence
Source: Christian BüttnerDr. Nunes, Büttner - WOST
Page 16
Bench and Sensitivity Analysis Validation
� Frequency identified
� Additional optimization to fix the problem Bench
FE
Sensitivity
Analysis
So
un
d P
ressu
reL
eve
l
Frequency
No
ise
In
dex
Bench
Dr. Nunes, Büttner - WOST
Page 17
Model Improvements
Dr. Nunes, Büttner - WOST
� Better Identification of main influences and
local minimum / maximum
� Better prediction of system behavior
Page 18
� Improvements in Modelling Brake System
� Better Identification of main influences
� Better prediction of system behavior
� Results fitting better with bench vehicles
� Using Sensitivity Analysis
� Identification of ideal parameter range
� Joint parameters haven‘t a strong influence
Conclusion
rigid
Kinematic CouplingRubber
Stiff Spring
Kinematic Coupling
Instability
Influence
Dr. Nunes, Büttner - WOST
Thank you for your attention !