A hybrid numerical-experimental methodology for robust assessment of automotive brake system noise

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Brake noise has been an issue for automotive manufacturers for decades and has led to customer perceived quality conditions, which in turn has a cost implication to manufacturers through warranty claims. It is a complex multifaceted problem. Although extensive research on brake noise has been conducted over decades, no comprehensive predictive methodology at the early design stage exists. Rather, a combination of dynamometer testing and finite element modeling techniques are used by the manufacturers to determine factors that may be influential in the aggravation of brake noise. These methods are employed at a stage when the brake system has already been finalized. This has led to noise control methods through complex changes to a combination of variables in an iterative process to reduce or eliminate noise conditions. These countermeasures are very keen to a particular brake system and are not applicable to other brake systems; hence, the process has to be repeated repeatedly for different brake systems resulting in a costly and time-consuming process. With the aim of mitigating this condition before reaching the final design, FCA (Fiat Chrysler Automobiles) is seeking to develop a more robust methodology, which has the ability to provide reliable and repeatable results, based on a better understanding of the sciences behind brake noise. This is the motivation behind this research. Its main objective is to develop a robust predictive tool that allows for a better understanding of the phenomena pertaining to brake noise with an emphasis on squeal noise. The main specification is to improve the correlation between the experimental and the numerical predictions so that the tool can be used at early design phases and processes rather than a diagnostic tool for existing systems. This will be achieved by adding uncertainty and variability in the modeling process with the help of experimental databases obtained with controlled laboratory experiments and dynamometer test rigs. More importantly, the tool will also predict disc brake sound radiation, a task often ignored in current tools and practices. The partner will be provided with an engineering tool together with the relevant methodologies dedicated to their brake noise prediction and design challenges. This knowledge toolbox will allow the partner a better engineering integration of brake system noise all along their products design cycle.**