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The analysis of the noise and vibration of drum brake systems
ㆍProduct: Drum Brake Systems
ㆍAnalysis Goal: Evaluate the vibration characteristics of a drum brake system and improve its design
Drum brake system
Drum brakes, which are widely used in trucks, buses, and some passenger vehicles, slow a vehicle using friction between semicircular brake shoes connected to the axle or suspension of the vehicle and the inside of a cylindrical drum mounted on the wheel. The friction coefficient between the shoes and the drum is a tunable characteristic that affects both the stopping performance and the vibration characteristics of the brake. A higher friction coefficient reduces the required forces acting on the shoes, but it also increases the vibration and reduces the stability of the drum brake system.
T o optimize the brake design, the multi flexible body dynamics software RecurDyn was used to reproduce the friction and vibration of the drum brake system during operation and evaluate its vibration and braking performance. A model of the brake system was created as a virtual twin of a physical drum brake system. This virtual twin was used to evaluate 2 different drum brake system designs.
Xuzhou Meritor Axle Co., Ltd China Postdoctoral Science Foundation funded project -No. 2012M521003 the National Basic Research Program of China-No. 2014CB049401
Process
① Created an MBD model of the drum brake system including the axle, brake shoes, and drum to reproduce its dynamic behavior.
② Created flexible bodies to predict the deformation and stress of the drum and shoes.
③ Analyzed the vibration characteristics under different friction coefficients between drum and shoes.
④ Evaluated the braking performance of 2 different designs with the same friction coefficient.
Key Technologies for Analysis of Drum Brake System
- Multi-body dynamics technology to predict the behavior of drum brakes
- Nonlinear contact algorithm to calculate the contact forces including friction between rigid bodies and flexible bodies
- Multi Flexible Body Dynamics (MFBD) technology that can accurately reproduce the deformation and stress of the drum and shoes as well as the motion of the drum brake system
Toolkits for Drum Brake System Simulation
- RecurDyn/Professional
- RecurDyn/TrackLM
Customer Challenges
- Need to identify the source of and improve the noise and vibration from the drum brake
- Early validation to verify if a new design meets the required braking performance specification
- Difficulty in analyzing the deformations and stresses in various parts of the drum brake system
Drum Brake System Simulation Results
Solutions for Drum Brake System Simulation
- The nonlinear contact algorithm that could successfully reproduce the vibration caused by the contact between the shoes and drum
- Quantitative evaluation of the change in vibration characteristics from a change in the friction coefficient
- Accurate prediction of the deformation and stress of the drum over time using transient MFBD technology
- Prediction of the braking performance difference between 2 different designs using virtual model
Outcomes
- New designs of drum brake system could be validated in an early stage using virtual models.
- Simulation results had good agreement with the physical results.
- After creating a virtual twin of the drum brake system in RecurDyn, this model can be used in the future for further development and analyses of the brake system.
Other Applications
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Parking brake simulation
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Brake simulation using flexible bodies
