Wagner, Andreas (2013):
Avoidance of brake squeal by a separation of the brake disc's eigenfrequencies: A structural optimization problem.
In: Forschungsberichte des Instituts für Mechanik der Technischen Universität Darmstadt, 31, Darmstadt, Studienbereich Mechanik, Technische Universität Darmstadt, TU Darmstadt, ISBN 978-3-935868-31-0,
[Online-Edition: http://tuprints.ulb.tu-darmstadt.de/3733],
[Ph.D. Thesis]

Abstract

Brake squeal is a high-pitched noise in the frequency range between 1 kHz and 16 kHz originating from self-excited vibrations caused by the frictional contact between brake pads and brake disc. Since some decades, it has intensively been studied and many countermeasures have been proposed, including active and passive methods. It is known from experiments and has also been proved mathematically that splitting the eigenfrequencies of the brake rotor has a stabilizing effect and avoids brake squeal. In this thesis, this knowledge is used to derive design goals for asymmetric, squeal-free discs. It is necessary to split all eigenfrequencies of the brake disc in a pre-definable frequency band to guarantee stability, inhibit the onset of self-excited vibrations and thus avoid squeal completely. In order to achieve this goal, a structural optimization of automotive as well as bicycle brake discs is conducted. Using a novel, efficient modeling technique, large changes in the geometry can be covered leading to a successful optimization in all cases studied. Optimized automotive and bicycle brake discs have been manufactured and tested on appropriate brake test rigs to assess their squeal affinity, and it is shown that the optimized discs have a greatly improved squeal behavior. This validates the mathematical theory behind the presented approach and demonstrates that splitting eigenfrequencies of the brake rotor is a passive, low-cost and effective squeal countermeasure applicable to a variety of brake systems.

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