Optimization of Two -Wheeler Braking Squeal Noise

Optimization of Two-Wheeler Braking Squeal Noise Reduction Using Solidworks and Finite Element Analysis

Anmol kumar1, *

, PV. Senthiil 2

1 Bachelor of Engg, Department of Mechanical Engineering, Saveetha School of Engineering, Saveetha University , Chennai, India 2 Professor, Department of Mechanical Engineering, Saveetha School of Engineering, Saveetha University , Chennai, India.

[email protected]

Abstract. This paper reviews that there is a type of noise which is creating amid the braking activity called

as Brake Squeal. Plate brake screech still keeps on being a noteworthy worry for the bike business

notwithstanding the endeavours to lessen its event amid the previous decades. It has been the subject of both

trial and numerical displaying since 1930s the constantly advancing desires identified with vehicle

execution have brought about the auto producer having to endeavour to give an aggressive and effective

stopping mechanism, as well as a 'calm' slowing mechanism. The end of brake screech clamour is vital as it

causes distress of the vehicle owners and in addition any people on foot. Screech issues may cause the auto

producer considerable income misfortune from guarantee claims related with the nature of clamour

delivered by the brake in spite of the way that the brake remains completely useful what's more, safe. The

exchange offs associated with this procedure keep on challenging designers to comprehend and control

brake clamour and vibration marvels. From a hypothetical point of view, circle brake screech can be named

a type of grinding prompted vibration. The trademark and the comprehension of this issue are confused by

the way that it is a transient marvel. The plate rotor, while acting like a speaker, is a pivoting part and the

collected brake joins numerous parts with complex interfaces. This movement is caused because of erosion

between the plate and the wheel. Because of this vast warmth is produced and brakes turn out to be

excessively hot which drives, making it impossible to the stopping of work since no a great part of the

warmth is permitted to disseminate. This sort of disappointment is called as brake blur. To enhance warm

dispersal and to reduce the squeal in our paper single material disc brake is used with different geometry

plate rotor is utilized to decide Disk screech. Demonstrating of the plate is been done on Solid works and

Modal examination is done on ANSYS 18.1

Keywords: braking noise, sequel sound, software applications.

1. INTRODUCTION

Taking out brake commotion is an exemplary test in the car

business. Brake plates grow vast and supported grating

incited motions, alluded to just as brake screech.

Two normal speculations portray brake screech marvels:

Stick-Slip Theory The self-energized vibration of a

slowing mechanism happens when the static grinding

coefficient is more prominent than the sliding grating

coefficient. Variable grating powers bring vitality into the

framework which isn't legitimately dispersed amid the

screeching occasion, bringing about huge vibration.

Mode-Coupling Theory When two comparative

trademark modes couple with each other, flimsiness is

acquainted with the slowing mechanism. This flimsiness is

caused basically by disgracefully chosen geometric

parameters. Both theories attribute brake squeal to variable

friction forces at the disc-pad interface.

Brake clamor is by and large classified as takes after:

Low-recurrence commotion - A case of a low-recurrence

clamor is the "moaning" clamor which happens in the

recurrence go in the vicinity of 100 and 1000 Hz. Any

clamor having a recurrence over 1000 Hz is viewed as a

screech

.

Low-recurrence screech - This screech is an aftereffect of

mode coupling happening between the out-of-plane

methods of the rotor and the bowing methods of the brake

cushion.

International Journal of Pure and Applied MathematicsVolume 119 No. 12 2018, 15561-15571ISSN: 1314-3395 (on-line version)url: http://www.ijpam.euSpecial Issue ijpam.eu

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High-recurrence screech - This screech is an aftereffect

of mode coupling happening between the in-plane methods

of the rotor.

Low-and high-recurrence screeching can be resolved

through complex Eigen solvers. The nearness of flimsy

modes recommends that the geometry parameters and

material properties of the slowing mechanism ought to be

changed

This paper proposes a way to deal with examine the

impacting components of the brake cushion on the circle

brake screech by coordinating limited component

(investigation) screech by coordinating limited component

(investigation) reproductions with solidworks (displaying)

methods. So as to decrease screech a pre-focused on

complex modular examination is connected to the brake

plate to investigate significance of rubbing impacts which

causes insecurity. This modular arrangement approach

depends on non-straight contact examination. Along these

lines outlines that causes disturbing break screech can be

distinguished in early improvement stages.

2. LITERATURE REVIEW

“D Rushikesh1.et al”, [1] It is now generally accepted that

brake squeal is caused by induced vibration. The squeal

can be reduced by increasing the friction coefficient and

decreasing the contact stiffness of the pad- disc system.

Brake temperature affects the brake pad stiffness, altering

the coupling mechanisms between the rotor and pad.

“Vignesh Shanbhag1, et al” [2] Cast iron has low squeal

compared to C-C Composite materials. Minimum squeal

was obtained at mode 1, i.e., 1190.4 Hz for cast iron and

1479.8 Hz for C-C composite material and Maximum

squeal was obtained at mode 6, i.e., 5426.3 Hz for cast iron

and 6754.0 Hz for C-C composite material. Both Cast iron

and C-C composite material squeal is with in the low

squeal frequency range. Better result of the squeal may be

because of ventilated brake disc. we can conclude that C-C

composite material is most suitable material for brake disc.

“Mr. Nitin Meghraj1, et al”, [3] No. of nodal diameter

decreases as natural frequencies increases all the six

samples of disk brakes. Natural frequencies of disc brake

of bike increase as the disc thickness decreases. Natural

frequencies of disc brake of bike decrease as the brake disc

holder hole diameter increases. Natural frequencies of disc

brake of bike decrease as the air ventilation hole diameter

increases.

“Hao Xing1”, [4] In this paper, we present a method of

brake squeal analysis with aid of ANSA and ABAQUS.

Complex modal analysis is employed to extract natural

frequencies and a transient analysis is carried out to study

the thermal effects during braking. The effect of friction in

complex modal analysis is investigated. The coupling of

thermal effect and squeal is to be studied in future.

“Abd Rahim1, et al” [5] This paper explores a proper way

of predicting unstable vibration using complex eigenvalue

analysis and transient analysis and attempts to investigate

the correlation between the two methods using a single

finite element package for a large degree-of-freedom

model of a disc brake. Three different contact schemes

available in ABAQUS are simulated for the complex

eigenvalue analysis and dynamic transient analysis.

“Mir Arash Keshavarz1” [6], Although the TDA analysis

gives a better overview about the brake transient

behaviour, it has some drawbacks that confine the utility of

this approach to just simple and “small” FE models. This

results in a limited application of this method to simplified

FEM models

“Abd Rahim Abu1, et al” [7] this paper attempts to

improve the drawbacks by considering temperature effect,

which is typically neglected by many previous

investigators. In doing so, a validated and detailed 3-D

finite element model of a real disc brake is used. Predicted

results are then compared to those obtained in the

experimental results with and without the effect of

temperature.

“P. Liu1, et al” [8] Friction-induced disc brake squeal is

investigated using the new function of ABAQUS version

6.4, which combines a nonlinear static analysis and a

complex eigenvalue extraction method. The squeal can be

reduced by decreasing the friction coefficient, increasing

the stiffness of the disc, using damping material on the

back of the pads, and modifying the shape of the brake

pads.

“D Rushikesh1, et al”

1 [9] this work presents Finite

Element modelling and modal analysis of disc-pad

assembly using high end software tools. Linear non-

prestressed modal analysis and full nonlinear perturbed

modal analysis is applied to predict frequency at which

squeal occurs. Real and imaginary Eigen frequencies of

unstable modes are obtained. Analysis is performed by

varying the coefficient of friction and outer diameter of

disc-pad assembly.

“Ibrahim Ahmed1, et al” [10] The results confirmed that

the eigenvectors of the leading and trailing brake shoes are

independent from each other with the same natural

frequency.

3. PROBLEM STATEMENT

In the course of brake operation, frictional heat is

dissipated mostly into pads and a disk, and an occasional

uneven temperature distribution on the components could

induce severe thermos elastic distortion of the disk. The

thermal distortion of a normally flat surface into a highly

deformed state, called thermos-elastic transition. It

sometimes occurs in a sequence of stable continuously

related states s operating conditions change. At other times,

however, the stable evolution behaviour of the sliding

system crosses a threshold whereupon a sudden change of

contact conditions occurs as the result of instability. This

invokes a feedback loop that comprises the localized

elevation of frictional heating, the resultant localized

bulging, a localized pressure increases as the result of

bulging, and further elevation of frictional heating as the

result of the pressure increase.

When vehicle is slowed down or stopped by using brake it

generates various kinds of noises. One of them is squeal.

This brake squeal is due to instability due to friction forces,

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leading to vibrations. To predict this instability, we can

perform modal analysis of prestressed structure.

OBJECTIVE & RESEARCH DESIGN

1) Modelling done in solidworks

2) Analyze same model by using ANSYS.

3) Optimization of design.

4) Redesign of disc

5) Analysis using ANSYS.

6) Conclusion

Fig 1: Disc Brake

4. METHODOLOGY

MECHANICAL MODELING

Ventilated disc brake has been designed in solidworks to

have proper heat dissipation & to reduce the surface

temperature, which will subsequently reduce the brake

squeal in the Disc brake.

SPECIFICATION

Rotor disc dimension

480 mm

Pad brake area 0.0067m2

Pad brake material Asbestos

Coefficient of friction (Dry) 0.3-0.5

Thickness 5mm

Maximum temperature 350 ºC

Maximum pressure

1Mpa

MATERIAL SELECTION

Rotor disc material ASTM G50 grey cast

iron, wear resistant, hard, good

heat absorption and dissipation.

DRAFTED MODEL

The solid model of disc pad assembly is modelled using

solidworks software tool. The disc has a thickness of 5 mm

and the brake pads have a thickness of 10 mm. The inner

diameter of the disc is 244 mm and outer diameter is of

450 mm

Fig 2: Disc Brake Drafted Model

BRAKE TORQUE (TB)

Assumption of equal coefficients of friction and normal

forces on the faces: -Eq.(1)

Where, TB = Brake torque

Brake torque helps to determine the diameter of the disc

brake

HEAT GENERATED THROUGH BRAKING Heat Generated in disc rotor (J/s) -Eq.(2)

Heat Flux (W/m2)

Where, mass of disc is 0.848

MODELS

Name MODIFICATION DESCRIPTION

Baseline

original

disc

MODEL 1

Original disc

with 4 auxiliary

holes 6mm dia

for disc holding,

with no holes

surrounding &

also with disc

pad.


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New

disc

with

inclined

holes

MODEL 2

New disc with 4

auxiliary holes

6mm dia & 33

surrounding

holes, inclined at

33 deg angle

from the center

& also with disc

pad.

New

disc

with

slot

holes

MODEL 3

New disc with 4

auxiliary 6mm

dia holes & 33

slotted holes has

been arranged &

also with disc

pad.

New

disc

with

crossed

holes

MODEL 4 New disc with 4

auxiliary holes

6mm dia & 33

holes of crossed

alignment has

been set up in

collaboration

with inclined

holes & also

with disc pad.

5. FINITE ELEMENT ANALYSIS (FEA)

MATERIAL PROPERTIES

PROPERTIES VALUES

Poissons ratio 0.3 Density 7800kg/m3

Young modulus(Nm-2

) 0.3

BOUNDARY CONDITION

The inner diameter of the cylinder hub and bolt holes is

constrained in all directions. Small pressure loading is

applied on both ends of the pad to establish contact with

the brake disc and to include prestress effects.

PROCEDURE

Mesh generation

Modal analysis

Linear non-prestressed analysis


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6. RESULTS

BASELINE ORIGINAL DISC

MODEL 1

MODEL 2

MODEL 3

MODEL 4

MODEL 5 MODEL 6


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NEW DISC WITH INCLINED HOLES

MODEL 1 MODEL 2

MODEL 3 MODEL 4

MODEL 5 MODEL 6


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NEW DISC WITH SLOT HOLES

MODEL 1 MODEL 2

MODEL 3 MODEL 4

MODEL 5 MODEL 6


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NEW DISC WITH CROSSED HOLES

MODEL 1 MODEL 2

MODEL 3 MODEL 4

MODEL 5 MODEL 6


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Crossed rows helps in reducing the heat and

helps to reduce the stress

Table 1 : crossed row hole disc

CROSSED ROW HOLE DISC

MODEL FREQUENCY (Hz) RESULT (MM)

1 59.792 27.249

2 116.01 55.977

3 123.52 47.205

4 128.62 49.47

5 194.46 37.74

6 268.31 31.612 Table 2: baseline disc

BASELINE DISC


1 61.482 27.081

2 115.82 54.516

3 123.49 48.819

4 130.1 50.889

5 195.94 37.201

6 274.59 31.234 Table 3: slot hole disc

SLOT HOLE DISC


1 58.772 27.38

2 114.73 56.912

3 122.3 50.31

4 125.62 52.001

5 193.97 38.598

6 258.86 31.856 Table 4: inclined hole disc

INCLINED HOLE DISC


1 60.783 27.18

2 115.88 55.725

3 123.98 41.991

4 128.81 44.493

5 195.48 37.571

6 271.36 30.924

7. GRAPHS

Graph 1: Crossed Row Vs Baseline Disc

Graph 2: Slot Ole Vs Inclined Hole

From the above given graphs, we conclude that the inclined hole disc brakes are much preferable rather

than other disc brakes as there deformation are less at prescribed natural frequency which simultaneously will reduce the vibration and significantly reduce the

heat transfer.

8. CONCLUSION

Automobile original equipped manufactures and suppliers

want to reduce warranty costs by delivering quieter brakes.

To accomplish this goal, they need the ability to evaluate

proposed brake designs to determine propensity to squeal,

all prior to building expensive and long-Leadtime

prototypes. The integrated approach described here offers a

breakthrough in that it provides all of the tools needed for

brake squeal prediction in a single integrated environment.

It saves time by reducing the need for data transfer and

automating routine analysis tasks. The new environment

also provides the ability to automatically simulate many

design points to quickly iterate to a design that meets noise


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requirements while delivering the best combination of

performance, cost, weight, size and other factors. The

ability to move directly to the optimal design helps to

improve customer satisfaction while reducing time to

market and lowering engineering costs.

9. REFERENCES

[1] D Rushikesh1.et al, “REVIEW ON DISC BRAKE

SQUEAL”, International Journal of Engineering Trends

and Technology (IJETT) – Volume 9 Number 12 - Mar

2014, PP (607-612)

[2] Vignesh Shanbhag1, et al, “MODELING AND

SQUEAL ANALYSIS OF BRAKEDISC ROTOR USING

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[3] Nitin Meghraj1, et al, “OPTIMIZATION OF A

BRAKING ROTOR OF TWO-WHEELER USING

ANSYS”., International journal of science, engineering and

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[4] S.Sindhuja, “GRAYSCALE IMAGE ANALYSIS

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[5] Hao Xing1, “

SQUEAL ANALYSIS OF DISC BRAKE

SYSTEM”, International Conference July 20081:207-231,

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[6] Abdul Rahim1, et al, “ COMPLEX EIGENVALUE

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Noise and Vibration, Vol. 2, No. 2, 2006 143, PP (11-16).

[7] Mir Arash Keshavarz1 ,“

BRAKE SQUEAL

ANALYSIS IN TIME DOMAIN USING ABAQUS

FINITE ELEMENT SIMULATION OF BRAKE

SQUEAL FOR PASSENGER CARS”., Int Journal

Sweden 2017, PP (22-25).

[8] Abd Rahim Abu1, et al, “STABILITY ANALYSIS

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TEMPERATURE EFFECT”,Universiti Teknologi

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Optimization of Two -Wheeler Braking Squeal Noise