To improve the prediction precision of complex modal model, both rig test and finite element model optimization were conducted. Firstly, three brakes were tested on a multi-function brake inertia dynamometer test bench, and the squeal frequencies were sampled from the point view of statistical analysis. Secondly, an optimized model was established based on the original brake squeal model by taking into account the caliper, bracket and the guide pins, and the frictional contact among these components. Finally, the precision of squeal frequencies were compared between the predictions of the original model and that of the optimized model. It was found that the squeal frequency statistics based on multi-conditions tests can effectively prevent the frequency-miss problem. And the careful considerations of components and their contact relations can effectively reduce the over-prediction and the under-prediction of instable frequencies, because they exert considerable effect on the shapes of several instable squeal modes.

Diao Kun, Zhang Lijun, Meng Dejian, Yu Zhuoping; - School of Automotive Engineering, Tongji University; New Clean Energy Vehicle Engineering Center