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Tribology International
journal homepage: www.elsevier.com/locate/triboint
Faculty of Environment and Information Sciences, Yokohama National University, 79-7 Tokiwadai, Hodogaya, Yokohama 240-8501, Japan
Faculty of Mechanical Engineering, Technical University of Liberec, Studentsk 1402/2, 461 17 Liberec I, Czech Republic
art ic l e i nf o
a b s t r a c t
Article history:
Received 1 March 2014
Received in revised form
27 April 2014
Accepted 28 April 2014
Available online 9 May 2014
A pad-on-disc-type brake apparatus was constructed based on a theoretical principle for suppressing
frictional vibration. The pad for this apparatus was supported by parallel leaf springs with a
unidirectional compliance. Braking tests were conducted using the apparatus under a constant normal
load. It has been found that a yaw angle misalignment between the directions of the pad and disc
motions provides a positive damping to suppress the frictional vibration and brake noise. In addition, it
has been also found that when an appropriate misalignment angle is selected, a low-noise performance
and a good braking performance can be achieved simultaneously.
& 2014 Elsevier Ltd. All rights reserved.
Keywords:
Disc brakes
Frictional vibration
Low-noise performance
Braking performance
1. Introduction
Brake noise is one of the classical problems for brake systems.
When brake noise occurs in an automobile, the passengers feel
uncomfortable. Therefore, it has long been thought to decrease the
commercial value of an automobile, and has been an important
problem requiring a solution. It is obvious that brake noise is
strongly related to frictional vibration because brake systems are
typical sliding systems. For example, Herv et al. [1] classied the
causes of the frictional vibration into four independent mechanisms:
stick-slip, velocity-weakening friction, sprag-slip, and mode-coupling
instability. Each of these mechanisms can cause frictional vibration
in brake systems leading to brake noise, and many researchers have
pointed out the relationships between brake noise and these
mechanisms of frictional vibration [216].
A variety of methods to eliminate brake noise have been proposed
from the viewpoints of the materials in contact [1214,1720] and
structural design [35,7,9,2124]. For example, from the viewpoints of
the materials in contact, Jang et al. [12,13] and Park et al. [14] proposed
a method to modify the velocity-weakening friction in brake systems
by changing the composition of the materials used in brake pads.
Meanwhile, from the viewpoint of structural design, Triches et al. [23]
showed that attaching an additional damping mechanism, which
Corresponding author.
E-mail address: nakano@ynu.ac.jp (K. Nakano).
http://dx.doi.org/10.1016/j.triboint.2014.04.033
0301-679X/& 2014 Elsevier Ltd. All rights reserved.
42
Nomenclature
c1
c2
F(V)
F(Vrel)
J
k
Lp
m
p
P
R
t
Tb
V
Vrel
W
2. Principle
Fig. 1 shows a model that describes the principle for suppressing frictional vibration in disc brake systems proposed by Nakano
et al. [25]. The x axis shows the direction of the disc velocity at
the contact between a pad and a disc. The and axes show the
principal axes of the stiffness for supporting the pad, where the
stiffness in the -axis direction is the smallest among the three
principal stiffnesses, and it is assumed for simplicity that the pad
moves only in the -axis direction. The angle between the x and
axes is the misalignment angle denoted by .
x, y, z
,
t
k(V)
k(Vrel)
eff
k (V)
, ,
cr
()
(0 )
()
axis
from
V:
misalignment angle
critical misalignment angle
disc angular velocity
derivative with respect to t
derivative with respect to Vrel
time average
cos
V cos _
V rel
Eq. (3) shows that if the pad velocity is changed, the direction
of the frictional force is changed autonomously.
Linearizing these equations around Vrel V, we obtain
m c1 c2 _ k FV cos
The two coefcients, c1 and c2, in the second term on the lefthand side of this equation are the effective damping coefcients
arising from the frictional force, dened as
c1 F 0 V cos 2
c2
Fig. 1. Theoretical model of disc brake system with yaw angle misalignment; :
misalignment angle.
FV sin 2
V
43
3. Experimental details
Fig. 3. Congurations of pad unit for 01, 451, and 901.
3.1. Apparatus
Fig. 2 shows a photograph and schematic diagram of the padon-disc-type brake apparatus that embodies the model of Fig. 1.
This apparatus employs a plane contact between a gray cast iron
disc (diameter: 250 mm, thickness: 10 mm, and arithmetic mean
roughness: 2.5 m) and a phenol resin pad (Youngs modulus:
5 GPa, diameter: 20 mm, and thickness: 5 mm). The disc is connected to a ywheel through a main shaft mounted in a bearing
unit so that the disc rotates freely around the shaft, where the
moment of inertia of the whole rotor is J 0.70 kgm2. A rotary
encoder connected to the shaft by a timing belt measures the disc
angular velocity . Meanwhile, the pad is supported by phosphor
bronze parallel leaf springs mounted on a z-axis linear guide. The
position of the pad is R 75 mm below from the rotational center
of the disc. A coil spring and a jack are placed in series behind the
parallel leaf springs to apply the normal load W to the contact by
using the spring force of the coil spring. A load cell placed in series
behind the jack measures the normal load. To measure the sound
pressure p of the brake noise, a microphone is mounted on the
extended line of the rotational axis at a distance of 100 mm from
the disc.
Fig. 3 shows the detailed structure around the pad. The xy plane
is parallel to the disc surface, and the x axis corresponds to the
direction of the disc velocity V at the contact between the pad and
the disc. The and axes show the principal axes of the parallel leaf
springs. The length, width, and thickness of the exposed part of a
leaf spring are 20 mm, 60 mm, and 0.6 mm, respectively; and the
distance between the two leaf springs is 40 mm. Therefore, the
stiffness of the parallel leaf springs in the -axis direction
(k 210 kN/m) is the smallest among the three principal stiffnesses.
The angle between the x and axes is the misalignment angle . In
this gure, three congurations for 01, 451, and 901 are shown as
examples. An acceleration sensor is mounted behind the pad for
measuring the pad accelerations in the - and -axis directions,
which are denoted by and , respectively.
3.2. Procedure
Using the pad-on-disc-type brake apparatus, braking tests were
conducted as follows. First, after cleaning the surfaces of the pad and
disc using ethanol, the running-in procedure was carried out at
01, W100 N, and V 1 m/s by rotating the disc manually until
the brake noise remained stable. Then, after setting under a noncontact condition, W100 N was applied again. Finally, the disc was
rotated up to 200 rpm manually. Then, during the free rotation of
the disc, the temporal changes in the disc angular velocity (), pad
accelerations ( and ), and sound pressure (p) were measured, at a
sampling rate of 40 kHz, by using the rotary encoder, acceleration
sensor, and microphone, respectively, until the disc was stopped
completely by the frictional force between the pad and the disc. The
braking test described above was conducted three times at values of
ranging from 01 to 901. All the tests were conducted at an ambient
temperature of 25 1C and a relative humidity of approximately 20%.
44
Fig. 4. Temporal changes in disc angular velocity (), pad accelerations ( and ), and sound pressure (p) for 01, 301, 601, and 901 at W 100 N.
in the brake time Tb. Among these, the highest value of eff
k (V) is
found when 301, leading to the shortest brake time Tb 3.30 s.
Considering that the frictional vibration is suppressed when
301 as shown in the second row of Fig. 4, the results on the
magnitude of eff
k (V) shown in Fig. 5 are consistent with those of
the experiments by Kado et al. [26], in which they measured the
kinetic frictional force using their anti-vibration tribometer and
found that the magnitude of eff
k (V) is increased by suppressing the
frictional vibration. The difference between k(V) and eff
k (V)
depends on the frictional property (i.e., k(Vrel)), mechanical
properties (i.e., m and k), and operating conditions (i.e., W and
V), which is induced not only by instantaneous change in the
relative velocity magnitude Vrel, but also by instantaneous change
in the frictional force direction , under the presence of even a
slight yaw angle misalignment 01 [27]. For example, for a steel
steel point contact lubricated by glycerol in the anti-vibration
tribometer, at most 40% decrease in eff
k (V) due to frictional
vibration has been conrmed [26,27].
P
J
VW
RW t
45
Fig. 6. Mean spectra of brake noise for 01, 301, 601, and 901 at W 100 N; PT: translational motion of pad in -axis direction; PR, PR, and PR: rotational motions of pad
about -, -, and -axis directions, respectively; and Dij: out-of-plane motion of disc with i nodal lines and j nodal circles.
Fig. 7. Effects of angular misalignment on brake noise (Lp) and brake time (Tb) at
W 100 N; symbols and error bars: mean values and standard deviations of three
measurements, respectively.
46
References
Fig. 8. Relationship between brake noise (Lp) and brake time (Tb) for 01901 at
W 100 N.
5. Conclusions
Based on a theoretical principle for suppressing the frictional
vibration from the viewpoint of structural design, a pad-on-disc-type
brake apparatus was constructed, the pad of which was supported by
parallel leaf springs having a unidirectional compliance. In braking
tests using the apparatus, the following conclusions were conrmed.
(1) The yaw angle misalignment between the directions of the pad
and disc motions provides positive damping to suppress the
frictional vibration caused by the velocity-weakening friction.
This eliminates the corresponding frequency component and
its harmonic components included in the brake noise.
(2) The appropriate misalignment angle to minimize the frictional
vibration and brake noise is approximately 301451. When the
appropriate angle is used, the effective kinetic friction coefcient is maximized, and thus a good low-noise performance
can be achieved with a good braking performance.
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