Complex Eigenvalue Analysis of Automotive Disc Brake Squeal with Automation

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Brake Squeal is an important and challenging phenomena to capture from an OEM’s perspective, to avoid expensive warranty issues and provide squeal proof driving experience to its customers. It becomes critical to identify and take corrective measures in the initial design phase, to avoid multiple and expensive test on prototypes. Complex eigenvalue analysis (CEA) to predict the squeal frequencies is a well-established approach since last two decades. However, CEA has always been a domain for the experienced analyst, unexplored by the designers. In this study, an attempt has been made to automate complete CEA procedure to evaluate brake squeal characteristics which guides a novice designer to begin with a 3D CAD model and end up with the squeal propensity evaluation. Above procedure includes complete automation of brake model setup, including material properties, contact creation, boundary conditions and the result generation using a template-based definition. It also allows more robust and concrete evaluation of contact characteristics which is quintessential for mode coupling phenomena that ultimately leads to brake squeal. Traditional techniques would take an experienced engineer, anywhere from few days to few weeks in performing CEA. Using this automation, the complete CEA analysis time can be reduced to just 3 to 4 hours, enabling designers to have deeper insights at a very early stage of brake design and development.

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