The purpose of this study is to understand, modify and control the vibrational behavior of a brake pad, by making changes only to the backplate geometry (ribs, cavities, holes, thickness without modifying the formulation of friction material or under layer, in order to shift or delete the critical frequencies harmful to the acoustic and vibrational comfort. The idea is to create a model sufficiently faithful to the real brake pad behavior in order to simulate these changes and reducing the typical times of "trial and error" approach.
A complete characterization of each component of the brake pad is the base to perform this study. To simplify the study we have taken in consideration the following methodology: the friction material has been considered as orthotropic material and characterized by IMS Etek 3000 machine following the standard measurement methodology (1,2) ; the under layer has been characterized by IMS Etek 3000 machine, but following a not standard procedure.
Once the C.A.E. model is ready end validated, we proceed to the study and to the choice the best backplate modifications by C.A.E. simulation. Selected the geometries we proceed to manufacture a backplate prototype (fine blanking production) and to the molding of brake pad in order to verify the reliability of the simulation.
Andrea Della Rovere, Daniele Donzelli, Luca Martinotto, Pietro Buonfico - ITT Italia Motion Technologies s.r.l.