盘式制动器制动噪声影响参数的有限元分析
摘要
随着人们对汽车舒适型的要求和环境保护的要求日益提高,汽车制动振动噪声受到越来越多的关注和研究。盘式制动器的制动振动噪声是一个复杂的非线性动力学问题,一直以来都是研究的重点和难点。
本文以某款存在高频制动振动噪声的盘式制动器为研究对象,从摩擦接触和复特征值分析等理论出发,应用有限元软件ANSYS研究分析了系统的不稳定模态的组成和各工况参数和材料属性参数的影响,以得到抑制噪声的有效措施。
首先建立制动器各零部件的有限元模型,进行有限元分析,得到它们的模态参数。然后在制动盘和块的摩擦面简建立接触关系,并且加入摩擦耦合,得到系统基于面接触的摩擦接触耦合有限元模型,并通过对整体耦合模型进行复特征值分析预测制动器产生制动振动噪声的不稳定模态和倾向。
再按照模态综合法,分析了不稳定模态各子结构模态构成,研究了各零部件的不同模态对制动器产生制动振动噪声不稳定模态的贡献。在系统前60阶的模态中有个别弹性模态与系统不稳定模态主频6788.1Hz相接近,但是大部分子结构模态频率与系统的不稳定模态主频相差很大。这说明简单分析子结构模态并认为其中频率和系统的不稳定模态主频相近的模态引起共振是诱发制动尖叫的方法并不完善的。
本文更主要的工作是通过改变摩擦系数,制动力,阻尼,温度等参数,建立更能反映实际工况的制动器有限元模型,计算分析了这些参数对系统稳定性的影响。根据分析得到：随着制动力增大,系统的不稳定性呈线性关系增长；随着温度的增加,系统在7KHz附近的不稳定模态减少,但是带来新的不稳定模态；高的摩擦系数容易导致系统的不稳定；随着随着材料阻尼损耗因子的增大,制动系统的不稳定模态主频明显下降,系统的稳定性得到明显改善。这些结论为制动振动噪声发生抑制措施的提出提供了理论依据。
Comfortable with the people's demand on car and the increasing requirements of environmental protection, brake noise and vibration have more and more attention and study. The brake noise is a complex nonlinear dynamics problem.
This thesis use finite element analysis software ANSYS to analysis the stability of the system and the impact of the work state parameters and material properties of parameters, from the frictional contact and the complex eigenvalue analysis theory, on a brake existing high-frequency brake vibration and noise, to get some measures for suppressing noise.
First, establish the finite element model of all brake parts for finite element analysis so that obtain their modal parameters. Then join the friction coupling and contact between the friction surfaces of the brake disc and pad to establish the contact coupled finite element model based on frictional contact surface. Also forecast the tendency and unstable mode of the brake noise through the eigenvalue analysis of whole complex coupling model.
Then in accordance with the mode synthesis, research all components'modal composition of the instability and the contribution of the various components' different modes on the unstable mode. There are some elastic modes in the system first 60 bands is close to the system instability mode 6788.1Hz,but most of the modal frequency and modal frequency instability of the system is so greatly different from the main mode. This shows that the simple analysis of components' mode and the viewpoint that the instability of the system is generated by resonance with the main mode frequency and it's similar is not perfect.
The more important work is to build a brake finite element model more realistic condition by changing the coefficient of friction, braking force, damping, temperature parameters,etc,and analyze the impact of these parameters on system stability.
According to the analysis:As brake power increases, the instability of the system is linear growth; as the temperature increases, the system unstable mode is reduced in the vicinity of 7KHz, but get some new unstable mode; high coefficient of friction will make the system unstable; with the increase of pad material damping loss factor, the unstable mode frequency of brake system is obviously decreased, and stability of the system is apparently improved. These conclusions provide a theoretical basis for making measures suppressing the brake vibration and noise.
本文以某款存在高频制动振动噪声的盘式制动器为研究对象,从摩擦接触和复特征值分析等理论出发,应用有限元软件ANSYS研究分析了系统的不稳定模态的组成和各工况参数和材料属性参数的影响,以得到抑制噪声的有效措施。
首先建立制动器各零部件的有限元模型,进行有限元分析,得到它们的模态参数。然后在制动盘和块的摩擦面简建立接触关系,并且加入摩擦耦合,得到系统基于面接触的摩擦接触耦合有限元模型,并通过对整体耦合模型进行复特征值分析预测制动器产生制动振动噪声的不稳定模态和倾向。
再按照模态综合法,分析了不稳定模态各子结构模态构成,研究了各零部件的不同模态对制动器产生制动振动噪声不稳定模态的贡献。在系统前60阶的模态中有个别弹性模态与系统不稳定模态主频6788.1Hz相接近,但是大部分子结构模态频率与系统的不稳定模态主频相差很大。这说明简单分析子结构模态并认为其中频率和系统的不稳定模态主频相近的模态引起共振是诱发制动尖叫的方法并不完善的。
本文更主要的工作是通过改变摩擦系数,制动力,阻尼,温度等参数,建立更能反映实际工况的制动器有限元模型,计算分析了这些参数对系统稳定性的影响。根据分析得到：随着制动力增大,系统的不稳定性呈线性关系增长；随着温度的增加,系统在7KHz附近的不稳定模态减少,但是带来新的不稳定模态；高的摩擦系数容易导致系统的不稳定；随着随着材料阻尼损耗因子的增大,制动系统的不稳定模态主频明显下降,系统的稳定性得到明显改善。这些结论为制动振动噪声发生抑制措施的提出提供了理论依据。
Comfortable with the people's demand on car and the increasing requirements of environmental protection, brake noise and vibration have more and more attention and study. The brake noise is a complex nonlinear dynamics problem.
This thesis use finite element analysis software ANSYS to analysis the stability of the system and the impact of the work state parameters and material properties of parameters, from the frictional contact and the complex eigenvalue analysis theory, on a brake existing high-frequency brake vibration and noise, to get some measures for suppressing noise.
First, establish the finite element model of all brake parts for finite element analysis so that obtain their modal parameters. Then join the friction coupling and contact between the friction surfaces of the brake disc and pad to establish the contact coupled finite element model based on frictional contact surface. Also forecast the tendency and unstable mode of the brake noise through the eigenvalue analysis of whole complex coupling model.
Then in accordance with the mode synthesis, research all components'modal composition of the instability and the contribution of the various components' different modes on the unstable mode. There are some elastic modes in the system first 60 bands is close to the system instability mode 6788.1Hz,but most of the modal frequency and modal frequency instability of the system is so greatly different from the main mode. This shows that the simple analysis of components' mode and the viewpoint that the instability of the system is generated by resonance with the main mode frequency and it's similar is not perfect.
The more important work is to build a brake finite element model more realistic condition by changing the coefficient of friction, braking force, damping, temperature parameters,etc,and analyze the impact of these parameters on system stability.
According to the analysis:As brake power increases, the instability of the system is linear growth; as the temperature increases, the system unstable mode is reduced in the vicinity of 7KHz, but get some new unstable mode; high coefficient of friction will make the system unstable; with the increase of pad material damping loss factor, the unstable mode frequency of brake system is obviously decreased, and stability of the system is apparently improved. These conclusions provide a theoretical basis for making measures suppressing the brake vibration and noise.
引文
[1]孙林.国内外汽车噪声法规和标准的发展.汽车工程,2000年(第22卷)第三期
[2]李建华.应用有限元法降低制动噪声的研究[D].吉林大学,2005
[3]王朝阳.汽车盘式制动器尖叫倾向性分析与设计改进[D].上海交通大学,2008
[4]周军现,张建寰,洪永强.盘式汽车制动器摩擦尖叫噪声机理研究[C]. China Academic Journal Electronic Publishing House,1994-2007
[5]管迪华,宿新东.制动振动噪声研究的回顾、发展与评述[C].工程力学,第21卷第4期2004年8月
[6]孙振华,曾庆华,蒋东鹰,等.盘式制动器制动尖叫的研究[c].汽车工程,99第6期
[7]孟宪皆,王欢,鞠丽娟.制动尖叫问题研究综述[C].山东理工大学学报(自然科学版),第21卷第6期2007年11月
[8]Oliviero Giannini, Francesco Massi. Characterization of the high-frequency squeal on a laboratory brake setup[C]. Journal of Sound and Vibration 310 (2008) 394-408
[9]黄学文,张金换,董光能,等.摩擦制动噪声防治研究进展[C].润滑与密封,2006年11月第11期(总第183期)
[10]Kinkaid N M,O'Reilly O M, Papadopoulos P. Automotive disc brake squeal[C]. Journal of Sound and Vibration 267 (2003) 105-166
[11]魏涛.基于ANSYS的盘式制动器结构分析及振动噪声研究.吉林大学硕士学位论文,2007
[12]Kreitlow W,et al. Vibration and "Hum" of disc brakes under load[C].SAE,Paper850079
[13]Abdelhamid M K.Brake judder anslysis:case study [C]. SAE, Paper 972027 1997
[14]Spurr R T. A theory of brake squeal[C]. Proc. Auto.Div..I MechE,1961,62:63-40
[15]Basford P R,Twiss S B.Properties of friction materials 2-theory of vibrations in brakes[C].Transactions of the ASME,1958,80:407-410
[16]Nishiwaki M. Generalized Theory of Brake Noise[C]. Proceeding of the Institution of Mechanical Engineers, PartD:Journal of Automobile Engineering,1993,207 (3):195-202.
[17]Ibrahim R A. Friction-induced Vibration, Chatter, Squeal, and Chaos, Part2:Dynamics andModeling[C]. Applied Mechanics Review,1994,47:227-253.
[18]Nishiwaki M. Generalized Theory of Brake Noise[C]. Journal of Sound and Vibration 291 (2006) 72-80
[19]KusanoM, et al. Experimental study on the reduction of drum brake noise [C]. SAE851465,1985
[20]Grolla D A,Lang A M. Brake noise and vibration-the state of the art,in:Dowson D.Taylor C M,Godet M,(Eds), Vehicle Tribology,Leeds,Englad,1991,pp,165-174
[21]Den Hartog J P. Mechanical Vibrations,4th Edition, McGraw-Hill, New York,1956
[22]Andrzej B,Vladimir B,Shih-Wei Kung. The influence of friction-induced damping and nonliner effects on brake squeal analysis[C].SAE2004-01-2794
[23]蒋东鹰,管迪华.盘式制动器制动尖叫计算模型的建立[C].汽车技术,1997年第7期
[24]管迪华,宿新东.利用结构动态特性优化设计抑制制动器尖叫[C],汽车工程,2003
[25]管迪华,黄锦春.盘式制动器尖叫的馈入能量分析[C].清华大学学报(自然科学版),2001年第41卷第8期
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[28]黄建新.盘式制动器制动尖叫影响因素分析[D].吉林大学,2007
[29]卓继志,谢伟东,宁晓斌.盘式制动器制动振动噪声问题的解决方案[C].机械设计与制造,第11期2007年11月
[30]黄学文,张金换,董光能,等.汽车摩擦制动噪声研究进展与发展趋势[C].2007年(第29卷)第5期
[31]葛振亮,吴永根,袁春静.汽车盘式制动器的研究进展[C].公路与汽运,2006
[32]AbuBakarl A R, Ouyang H, James S, and et al. Finite element analysis of wear and its effect on squeal Generation. IMechE 2008
[33]Filip B, Mikael E, Staffan J. Influence of disc topography on generation of brake squeal[C]. Wear 225-229_1999.621-628
[34]Linck V, Baillet L, Berthier Y. Modeling the consequences of local kinematics of the first body on friction and on third body sources in wear[C]. Wear 255 (2003) 299-308
[35]Mikael E, Filip B, Staffan J. Surface characterisation of brake pads after running under silent and squealing conditions[C]. Wear 232_1999.163-167
[36]Francesco M, Yves B, Laurent B. Contact surface topography and system dynamics of brake squeal[C]. Wear 265 (2008) 1784-1792
[37]Mikael E, Filip B, Staffan J. On the nature of tribological contact in automotive brakes[C]. Wear 252 (2002) 26-36
[38]董文军,谢伟松译.有限元分析[M]。北京：科学出版社,2002
[39]何军毅,林祥都.工程结构非线性问题的数值解法[M]。北京：国防工业出版社,1994
[40]李兆霞,郭力.工程弹性力学[M],南京：东南大学出版社,2009
[41]诸德超,邢誉峰.工程振动基础[M].北京：北京航空航天大学出版社,2004
[42]晏砺堂,朱梓根,李其汉.高速旋转机械振动[M].北京：国防工业出版社,1994
[43]许本文.机械振动与模态分析基础[M]。北京：机械工业出版社,1998
[44]曹树谦,张文德,萧龙翔.振动结构模态分析：理论、实验与应用[M]。天津：天津大学出版社,2001年3月
[45]Brooks P C, Crolla D A, Lang A M, et al. Eigenvalue sensitivity analysis applied to disc brake squeal, in Braking of Road Vehicles [M]. Mechanical Engineering Publications Limited:Institution of Mechanical Engineers,1993.
[46]Dihua Guan, Xindong Su, Fang Zhang. Sensitivity analysis of brake squeal tendency to substructures'modal parameters[C]. Journal of Sound and Vibration 291 (2006) 72-80
[47]Shih-Wei Kung, K. Brent Dunlap, Robert S. Ballinger.. Complex eigenvalue analysis for reducing low frequency brake squeal[C].SAE2000-01-0444,2000
[48]刘相新,孟宪颐.ANSYS基础与应用教程.北京：科学出版社,2006
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[53]郑林庆.摩擦学原理[M].北京：高等教育出版社,1994
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[57]王登峰,王玉为,黄海涛等.盘式制动器制动尖叫的有限元分析与试验[C].汽车工程,2007年(第29卷)第8期
[58]国家标准GB5763-1998《汽车用制动器衬片》
[59]Dihua Guan, Dongying Jiang. A study on disc brake squeal using finite elemt methods[C]. SAE Paper 980597
[60]Mario Triche s Junior, Samir N.Y. Gerges*, Roberto Jordan. Analysis of brake squeal noise using the finite element method:A parametric study[C]. Applied Acoustics 69 (2008) 147-162
[2]李建华.应用有限元法降低制动噪声的研究[D].吉林大学,2005
[3]王朝阳.汽车盘式制动器尖叫倾向性分析与设计改进[D].上海交通大学,2008
[4]周军现,张建寰,洪永强.盘式汽车制动器摩擦尖叫噪声机理研究[C]. China Academic Journal Electronic Publishing House,1994-2007
[5]管迪华,宿新东.制动振动噪声研究的回顾、发展与评述[C].工程力学,第21卷第4期2004年8月
[6]孙振华,曾庆华,蒋东鹰,等.盘式制动器制动尖叫的研究[c].汽车工程,99第6期
[7]孟宪皆,王欢,鞠丽娟.制动尖叫问题研究综述[C].山东理工大学学报(自然科学版),第21卷第6期2007年11月
[8]Oliviero Giannini, Francesco Massi. Characterization of the high-frequency squeal on a laboratory brake setup[C]. Journal of Sound and Vibration 310 (2008) 394-408
[9]黄学文,张金换,董光能,等.摩擦制动噪声防治研究进展[C].润滑与密封,2006年11月第11期(总第183期)
[10]Kinkaid N M,O'Reilly O M, Papadopoulos P. Automotive disc brake squeal[C]. Journal of Sound and Vibration 267 (2003) 105-166
[11]魏涛.基于ANSYS的盘式制动器结构分析及振动噪声研究.吉林大学硕士学位论文,2007
[12]Kreitlow W,et al. Vibration and "Hum" of disc brakes under load[C].SAE,Paper850079
[13]Abdelhamid M K.Brake judder anslysis:case study [C]. SAE, Paper 972027 1997
[14]Spurr R T. A theory of brake squeal[C]. Proc. Auto.Div..I MechE,1961,62:63-40
[15]Basford P R,Twiss S B.Properties of friction materials 2-theory of vibrations in brakes[C].Transactions of the ASME,1958,80:407-410
[16]Nishiwaki M. Generalized Theory of Brake Noise[C]. Proceeding of the Institution of Mechanical Engineers, PartD:Journal of Automobile Engineering,1993,207 (3):195-202.
[17]Ibrahim R A. Friction-induced Vibration, Chatter, Squeal, and Chaos, Part2:Dynamics andModeling[C]. Applied Mechanics Review,1994,47:227-253.
[18]Nishiwaki M. Generalized Theory of Brake Noise[C]. Journal of Sound and Vibration 291 (2006) 72-80
[19]KusanoM, et al. Experimental study on the reduction of drum brake noise [C]. SAE851465,1985
[20]Grolla D A,Lang A M. Brake noise and vibration-the state of the art,in:Dowson D.Taylor C M,Godet M,(Eds), Vehicle Tribology,Leeds,Englad,1991,pp,165-174
[21]Den Hartog J P. Mechanical Vibrations,4th Edition, McGraw-Hill, New York,1956
[22]Andrzej B,Vladimir B,Shih-Wei Kung. The influence of friction-induced damping and nonliner effects on brake squeal analysis[C].SAE2004-01-2794
[23]蒋东鹰,管迪华.盘式制动器制动尖叫计算模型的建立[C].汽车技术,1997年第7期
[24]管迪华,宿新东.利用结构动态特性优化设计抑制制动器尖叫[C],汽车工程,2003
[25]管迪华,黄锦春.盘式制动器尖叫的馈入能量分析[C].清华大学学报(自然科学版),2001年第41卷第8期
[26]陈小悦.鼓式制动器低频振颤的研究[D],清华大学,1988
[27]胡朝峰,过学迅.车辆制动科学技术的发展与研究进展[J],武汉理工大学
[28]黄建新.盘式制动器制动尖叫影响因素分析[D].吉林大学,2007
[29]卓继志,谢伟东,宁晓斌.盘式制动器制动振动噪声问题的解决方案[C].机械设计与制造,第11期2007年11月
[30]黄学文,张金换,董光能,等.汽车摩擦制动噪声研究进展与发展趋势[C].2007年(第29卷)第5期
[31]葛振亮,吴永根,袁春静.汽车盘式制动器的研究进展[C].公路与汽运,2006
[32]AbuBakarl A R, Ouyang H, James S, and et al. Finite element analysis of wear and its effect on squeal Generation. IMechE 2008
[33]Filip B, Mikael E, Staffan J. Influence of disc topography on generation of brake squeal[C]. Wear 225-229_1999.621-628
[34]Linck V, Baillet L, Berthier Y. Modeling the consequences of local kinematics of the first body on friction and on third body sources in wear[C]. Wear 255 (2003) 299-308
[35]Mikael E, Filip B, Staffan J. Surface characterisation of brake pads after running under silent and squealing conditions[C]. Wear 232_1999.163-167
[36]Francesco M, Yves B, Laurent B. Contact surface topography and system dynamics of brake squeal[C]. Wear 265 (2008) 1784-1792
[37]Mikael E, Filip B, Staffan J. On the nature of tribological contact in automotive brakes[C]. Wear 252 (2002) 26-36
[38]董文军,谢伟松译.有限元分析[M]。北京：科学出版社,2002
[39]何军毅,林祥都.工程结构非线性问题的数值解法[M]。北京：国防工业出版社,1994
[40]李兆霞,郭力.工程弹性力学[M],南京：东南大学出版社,2009
[41]诸德超,邢誉峰.工程振动基础[M].北京：北京航空航天大学出版社,2004
[42]晏砺堂,朱梓根,李其汉.高速旋转机械振动[M].北京：国防工业出版社,1994
[43]许本文.机械振动与模态分析基础[M]。北京：机械工业出版社,1998
[44]曹树谦,张文德,萧龙翔.振动结构模态分析：理论、实验与应用[M]。天津：天津大学出版社,2001年3月
[45]Brooks P C, Crolla D A, Lang A M, et al. Eigenvalue sensitivity analysis applied to disc brake squeal, in Braking of Road Vehicles [M]. Mechanical Engineering Publications Limited:Institution of Mechanical Engineers,1993.
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