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CHAPTER 3
MODAL ANALYSIS OF DISC BRAKE ASSEMBLY
3.1
INTRODUCTION
Finite element analysis (FEA) is widely used to model the dynamic
response of a structure and has the advantage that complex geometries can be
accurately modeled. But accuracy of the FEA can be questionable and the
reliability of the FE model must be validated by comparing the predicted
results of natural frequencies and mode shapes of the FE model with the
experimental results.
In this chapter, FE models of the disc brake components and
assembly are developed using FE software (ABAQUS 6-8). In order to ensure
that accuracy of the FE model agree with those of the physical components,
two validation stages are used through experimental measurements at both
individual component and at assembly levels. First, FE modal analysis at the
component level is carried out and simulated up to frequencies of 10 kHz.
Then, the mesh sensitivity of the each disc brake components is considered. In
order to correct the predicted frequencies with the experimental results, a FE
updating is used to reduce relative errors between the two sets of results by
tuning the material. Finally, the integrated brake assembly model is corrected
with measured data using proper contact interaction between brake
components. The methodology used for validation of FE model will be
discussed
Figure 3.1.
in
the
following
sections,
as
shown
in
52
53
Impact hammer
Excitation of the structure is the most critical point of EMA. There
54
55
3.2.1.2
Accelerometer
For the present experiments, accelerometer (Kistler 8628 B50) with
excitation and response signals from the hammer and the accelerometer are
acquired through a four-channel analyzer (DEWE-41-T-DSA). The sensitivity
information of the sensors is used to calculate the values for the acceleration
and the force. The DSA also performs the transformations to convert the
measured time domain signals into FRFs.
3.2.2
Experimental Procedure
Generally, the frequency domain of EMA can be classified into
three different types based on the number of FRFs which are to be included
in the analysis (Ewins 2001). The simplest of the three methods is referred to
as SISO (Single Input, Single Output) which involves measuring a single FRF
for a single input given. A SISO data set is made of a set of FRFs which are
measured individually but sequentially at different points on the structure.
The second test method is referred to as SIMO (Single Input, Multiple
Output). This refers to a set of FRFs measured simultaneously at different
locations for a single input given at a specific location. The third method is
referred to as MIMO (Multiple Input, Multiple Output) in which the FRFs at
56
3.2.3
57
3.2.4
factor and mode shape) the geometry of the disc brake components is created
in commercial software (DEWE/FRF) to define the various points on which
excitation is given in the experimental and the points at which response is
measured. Once the geometry is created, the measured FRFs are given as
input at the respective points at which they are measured. The extraction of
modal parameters from the measured FRFs is a curve fitting problem. Many
curve fitting methods are available but for the present application, circle
fitting method is adopted to extract the mode shapes and natural frequencies
from the geometry. The modal peak function is calculated by summing
together the real parts, imaginary parts or magnitudes of all transfer functions
in the data block file that is being curve fitted. In this study, the modal peak
function is found to be the most appropriate which can be easily reveal the
natural frequencies of the structures for further study and validate with FE
results.
In experimental modal testing, one of the tools used to ensure the
quality of the acquired signal is coherence (Ewins 2001). Coherence can have
a maximum value of one and a minimum value of zero. Coherence value of
one indicates that the response measured is entirely due to the given input
excitation and value of zero indicates that the measured response is entirely
due to some other excitation than the given excitation. From Figure 3.3, it can
be seen that for the frequency range of interest up to 10 kHz, the coherence
function is one for all the trials conducted. Hence the measured response is
taken as the result of given input excitation.
58
59
(i)
Rotor
The modal analysis of rotor plays an important role in
plane and radial in-plane modes is possible. The vibration responses at all the
nodes are measured with accelerometers. The modal parameters are
determined using the software (DEWE/ FRF) and bending modes have the
highest modal peaks. Figure 3.5 shows the experimental FRF of the rotor.
Amplitude (m/s^2)/N
0
0
2000
4000
6000
Frequency (Hz)
8000
10000
60
(ii)
Brake pad
The modal analysis of the pad is carried out on the backing plate of
the pad. The pad grid consisted of 17 points, the accelerometer fixed at
middle point and the excitation in out-of-plane direction is applied to the rest
of points. It is found that only two bending modes are identified over the
frequency range, as shown in Figure 3.6.
Amplitude (m/s^2)/N
0
0
2000
4000
6000
8000
10000
Frequency (Hz)
Caliper
The caliper grid consisted of 30 points at different position on the
outer surface in all three coordinates. The accelerometer is fixed at the middle
surface of the caliper housing and excitation is conducted on all points to
capture as much of the vibration characteristics as possible. Figure 3.7 shows
the experimental FRF of the caliper.
61
Amplitude (m/s^2)/N
0
0
2000
4000
6000
8000
10000
Frequency (Hz)
Anchor bracket
The anchor bracket grid is constructed for 22 points and the
12
Amplitude (m/s^2)/N
10
0
0
2000
4000
6000
8000
10000
Frequency (Hz)
Knuckle assembly
Knuckle assembly consists of steering knuckle and wheel hub. The
62
surface of the assembly. Figure 3.9 shows the experimental FRF of the
knuckle assembly.
12
Amplitude (m/s^2)/N
10
0
0
2000
4000
6000
8000
10000
Frequency (Hz)
Piston
From the modal analysis of the piston, it is found that only one
Amplitude (m/s^2)/N
30
20
10
0
0
2000
4000
6000
Frequency (Hz)
8000
10000
63
3.2.5.2
Amplitude (m/s^2)/N
0
0
2000
4000
6000
8000
Frequency (Hz)
10000
64
3.3
65
3.3.1
Mesh Sensitivity
The accuracy of the results of FEM is very much dependent on the
Mode No.
Coarse mesh
1256 element
Fine mesh
2559 element
Difference ratio
1,2
1473
1453
1430
1.5%
3,4
3289
3225
3133
2.8%
5,6
5169
5062
4887
3.4%
7,8
7234
7067
6799
3.8%
9,10
9421
9170
8788
4.1%
66
3.3.2
FE Model Updating
The aim of FE updating is to reduce maximum relative errors
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Components
3.3.3
Rotor
7155
125
0.23
Friction material
2045
2.6
0.34
Back plate
7850
210
0.3
Caliper
7005
171
0.27
Anchor bracket
7050
166
0.27
Steering knuckle
7625
167
0.29
Wheel hub
7390
168
0.29
Piston
8018
193
0.27
Guide pin
2850
71
0.3
Bolts
7860
210
0.3
FE Modal Results
FE modal analysis of the disc brake components and assembly is
68
3.14. The node and anti-node should appear in the response frequency
diagram as peak and anti-peak.
(i)
Rotor
After conducting mesh sensitivity calculation the final FE model of
the rotor consists of 2559 solid elements of type C3D8 with 4988 nodes. With
this FE model modal analysis is carried on the rotor. There are number of
natural frequencies and mode shapes exhibited in the FE results. However,
only nodal diameter (ND) type mode shapes are considered to compare with
experimental results, as illustrated in Figure 3.15.
Rotors are always one of the key factors in brake squeal. Squeal
frequencies are often at or close to rotors resonant frequencies. The rotor is
made of cast iron; the Youngs modulus of cast iron depends on carbon
content, and, to a lesser extent, silicon content. The most reliable way to set
the material properties is to tune them to the experimentally determined
modal properties. Based on the tuning process for the rotor properties, the
predicted results are close to the measured as shown in Table 3.3.
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Brake pad
The brake pad consists of two parts: the friction material and a stiff
back plate. The back plate is made of steel and serves to support the friction
70
Caliper
The FE model of the caliper consists of 2334 solid elements and
2370 nodes. The caliper is made of ductile cast iron. The modal analysis is
71
conducted and the frequencies and shape modes are obtained as shown in
Figure 3.17. Material properties are adjusted to match modal frequencies of
FEA and EMA results by using the same steps used for validation of the rotor.
The results of the predicted results show good agreement with the measured
data as shown in Table 3.3.
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(iv)
Anchor bracket
The FE model of anchor bracket consists of 1036 solid elements
and 1644 nodes. Figure 3.18 shows the natural frequencies and mode shapes
of the bracket. A comparison of the anchor bracket frequencies obtained from
FEA is done with those found in experimental modal test is given in Table 3.3.
Knuckle assembly
The FE model of the steering knuckle which consists of 9868 solid
elements and 3585 nodes is created and merged with wheel hub model which
consists of 1654 solid elements types C3D8 and 2786 nodes. The FE modal
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analysis is conducted on the knuckle assembly and the mode shapes are
plotted in Figure 3.19. Comparison between the FE and experimental modal
analysis is listed in Table 3.3. It is found that there is a good agreement
between the two results.
74
(vi)
Piston
The FE model of piston consists of 357 solid elements types C3D8
and 576 nodes. Figure 3.20 shows mode shape at frequency of 7392 Hz.
There is only one natural frequency of the piston in the range of interest. The
predicted result from FEA is compared with experimental modal analysis and
it is found that a good agreement with the predicted and measured data.
bolts and guide pin due to difficulty to get acceptable results using
experimental test. From the FE modal analysis, there are two modes found
within the frequency range of interest, as shown in Figure 3.21.
Figure 3.21 Guide-pin and bolts natural frequencies and mode shapes
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Rotor
Anchor bracket
Caliper
Brake Pad
piston
Steering knuckle
and wheel hub
1464
1453
-0.7
3198
3225
0.8
4992
5062
1.4
6958
7067
1.5
9020
9170
1.6
878
880
0.2
1770
1755
-0.8
3341
3164
-5.2
4675
4680
0.01
7067
7533
6.5
9387
9262
-1.3
2282
2293
-1.7
3769
3960
5651
5667
0.2
6909
6587
-4.6
8569
8221
-4.0
2819
2889
2.4
7067
6735
-4.6
7287
7392
1.4
1232
1211
-1.7
2138
2242
4.8
4856
4421
-8.9
6401
6389
8214
7995
-2.6
8856
8665
-2.2
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3.3.3.2
between
all
components.
The
natural
frequencies
and
77
Figure 3.22 Spring contact and direct contact between disc brake
78
3.4
1611
1562
-3
3222
3174
-1.4
5065
5184
2.3
6933
6597
-4.8
9020
9452
4.7
CONCLUDING REMARKS
In this chapter, a comprehensive method for conducting modal