基于ANSYS的盘式制动器振动噪声分析与研究
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摘要
随着经济的迅速发展,汽车已经进入普通老百姓的家庭,极大地方便了人们的日常生活和工作。人们对汽车舒适性方面的要求也迅速向国际水平靠拢,购买汽车的时候,人们不仅仅关注汽车的价格、安全性,同时对汽车振动噪声等与舒适性相关的要求也越来越高。随着汽车技术的不断进步,车内振动与噪声明显降低,而一些子系统和零部件的振动噪声问题(例如制动器的振动噪声问题),变得越来越突出,因此对制动器进行振动噪声方面的研究显得非常重要。这对制动器的结构设计具有重要的实用价值。
本文首先介绍了有限元的思想和有限元分析的几种常用的软件,然后以国产某型汽车为例,假设制动力矩均匀分布,经过简化计算求出制动盘、制动片、制动支架的制动力矩。然后建立制动器各构件的CAD模型,考虑到划分网格的需要,建模的时候忽略了构件中一些不重要的凹台和圆角,采用mapped法将建立的模型网格化,确定合适的边界条件和自由度,将制动力矩加载到制动器的有限元模型上,进行结构分析和模态分析。
分析结果表明:制动盘的固有频率在368～699Hz之间,制动盘的动刚度不足;制动片的尖角部位有应力集中;制动支架的动刚度不足。同时各部件的不同阶频率有重合的情况,容易引起结构共振。希望采用改变厚度,尖角部位倒圆角,同时在制动盘上开设通风道的等办法来降低振动噪声产生的概率。
将优化设计后的模型导入ANSYS中,重新进行模态分析,结果显示各个构件的应力集中的情况有了较大的改善,固有频率都有所升高,但是外界的激励频率一般比较小,同时不同阶频率重合的现象也有所改善,在理论上减少了振动噪声发生的概率,这种降低盘式制动器振动噪音的方法有待进一步通过试验鉴定。
本文的工作主要在于用模态分析的方法分析制动器振动噪声的发生源,这种方法不仅适用于分析制动器,而且为机械设备中相互耦合的部件之间的振动噪声的检测,提供了一种可以借鉴的降低振动噪声方法。
With the rapid development of Chinese enconomy, vehicles have used by ordinary people's families and given more convenience to people's life and work. Now customer's expectations for new vehicles are not only high safety and low price, but aslo high comfortableness, such as low vibration noise. With the development of automobile technology, the noise and vibration of the whole vehicle are decreased very much, but the vibration noise of the parts and subsystems such as brakes becomes more and more prominent. So the rearch on vibration noise in brakes are more important than before, its results will be valuable for the structure design of brake.
In this thesis, the principle of finite element and several common softwares of finite element analysis are introduced firstly, and then some type of the car made by Chinese company have been taken for example. Though simplified calculation, it is supposed that the distribution of the braking moment is uniform, then the braking moments of its disc, block and anchorage are determined. For establishing the CAD model of the components of the brake, the grid division of the model are taken into account, and those unimportant concaves and fillets are also overlooked.
By means of the mapped method, the appropriate boundary conditions and degrees of freedom for the established model grid are determined. Meaningwhile, the braking moment will be loaded on the finite element model for the mode and structure analysis.
The results showed that when the natural frequency of brake disc is between 368～699Hz; the dynamic stiffness of brake disc is not enough, there is stress concentration at the sharp angles of the brake block; the dynamic stiffness of the brake anchorage is deficient. When there is the coincidence phenomenon of the frequencies of the different steps for brake parts, the resonant phenomenon will occur. For reducing vibration noise of the brake, the frequency will be reduced by means of some methods such as changing the thickness, making fillets at the sharp angles and opening the ventilations at the brake disc.
The design model optimized is put in ANSYS, the modal analysis is made again, its results shows that situation of stress concentration is improve tremendous and the natural frequencies of various components have been increased. Because the external excitative frequency is generally very low, the coincidence phenomenon of different frequency bands has been also improved. These methods decrease the vibration noise effectively. This improvement method will be tested further.
The significance of this thesis is to present the method of analyzing the reasons of brake vibration noise by means of the modal analysis principle. This method applies not only to the noise detection for the brake, but also to the noise detection for the mutual coupling components in machinery industry, and it will provide a new method for the noise detection in engineering.
本文首先介绍了有限元的思想和有限元分析的几种常用的软件,然后以国产某型汽车为例,假设制动力矩均匀分布,经过简化计算求出制动盘、制动片、制动支架的制动力矩。然后建立制动器各构件的CAD模型,考虑到划分网格的需要,建模的时候忽略了构件中一些不重要的凹台和圆角,采用mapped法将建立的模型网格化,确定合适的边界条件和自由度,将制动力矩加载到制动器的有限元模型上,进行结构分析和模态分析。
分析结果表明:制动盘的固有频率在368～699Hz之间,制动盘的动刚度不足;制动片的尖角部位有应力集中;制动支架的动刚度不足。同时各部件的不同阶频率有重合的情况,容易引起结构共振。希望采用改变厚度,尖角部位倒圆角,同时在制动盘上开设通风道的等办法来降低振动噪声产生的概率。
将优化设计后的模型导入ANSYS中,重新进行模态分析,结果显示各个构件的应力集中的情况有了较大的改善,固有频率都有所升高,但是外界的激励频率一般比较小,同时不同阶频率重合的现象也有所改善,在理论上减少了振动噪声发生的概率,这种降低盘式制动器振动噪音的方法有待进一步通过试验鉴定。
本文的工作主要在于用模态分析的方法分析制动器振动噪声的发生源,这种方法不仅适用于分析制动器,而且为机械设备中相互耦合的部件之间的振动噪声的检测,提供了一种可以借鉴的降低振动噪声方法。
With the rapid development of Chinese enconomy, vehicles have used by ordinary people's families and given more convenience to people's life and work. Now customer's expectations for new vehicles are not only high safety and low price, but aslo high comfortableness, such as low vibration noise. With the development of automobile technology, the noise and vibration of the whole vehicle are decreased very much, but the vibration noise of the parts and subsystems such as brakes becomes more and more prominent. So the rearch on vibration noise in brakes are more important than before, its results will be valuable for the structure design of brake.
In this thesis, the principle of finite element and several common softwares of finite element analysis are introduced firstly, and then some type of the car made by Chinese company have been taken for example. Though simplified calculation, it is supposed that the distribution of the braking moment is uniform, then the braking moments of its disc, block and anchorage are determined. For establishing the CAD model of the components of the brake, the grid division of the model are taken into account, and those unimportant concaves and fillets are also overlooked.
By means of the mapped method, the appropriate boundary conditions and degrees of freedom for the established model grid are determined. Meaningwhile, the braking moment will be loaded on the finite element model for the mode and structure analysis.
The results showed that when the natural frequency of brake disc is between 368～699Hz; the dynamic stiffness of brake disc is not enough, there is stress concentration at the sharp angles of the brake block; the dynamic stiffness of the brake anchorage is deficient. When there is the coincidence phenomenon of the frequencies of the different steps for brake parts, the resonant phenomenon will occur. For reducing vibration noise of the brake, the frequency will be reduced by means of some methods such as changing the thickness, making fillets at the sharp angles and opening the ventilations at the brake disc.
The design model optimized is put in ANSYS, the modal analysis is made again, its results shows that situation of stress concentration is improve tremendous and the natural frequencies of various components have been increased. Because the external excitative frequency is generally very low, the coincidence phenomenon of different frequency bands has been also improved. These methods decrease the vibration noise effectively. This improvement method will be tested further.
The significance of this thesis is to present the method of analyzing the reasons of brake vibration noise by means of the modal analysis principle. This method applies not only to the noise detection for the brake, but also to the noise detection for the mutual coupling components in machinery industry, and it will provide a new method for the noise detection in engineering.
引文
[1]主安成,高诚辉.盘式制动器噪声机理研究及其声场的数值模拟.中国优秀硕士学位论文全文数据库:福州大学,2006年5月
[2]庞剑,谌刚,何华.汽车噪声与振动理论与应用.北京:北京理工大学出版社,2006:15
[3]李以农,郑玲,曾励.汽车制动噪声研究状况及存在的问题.北京:北京理工大学出版社,1994,3:36-38
[4]吴剑增.汽车制动噪声产生的原因及影响.汽车与环保,1994,3:25-30
[5]Coonki Park,Min Gyu Han,Sung Sun Choetal.A Study on the Reduction of the DiskBrake Squeal Using Complex Eigenvalue Analysis.SAE2001-01-3141,2001
[6]管迪华,宿新东.制动振动噪声研究的回顾、发展与评述.工程力学,2004,8:150-155
[7]RheeS K,et al.The role of friction film in friction,wear and noise of automotive brakes.Wear 1991,146:89-97
[8]Millner N.An analysis of disc brake squeal.SAE780332,1978
[9]SinelairD,ManwillNJ.FrictionVibratlon..APP.meeh.,1955(22)
[10]黄士振.有限元法.南京:南京理工大学,1986
[11]Spurr R T.Brake squeal.l Mech E,1971,95/71:13-15
[12]Millner N.A theory of drum brake squeal.I Mech E,1976,c39/76:10-185
[13]陈世雄,鼓式制动器制动尖叫的研究.中国优秀硕士学位论文全文数据库:清华大学,1988
[14]陈光雄,周仲荣,谢友柏.摩擦噪声研究的现状和进展.摩擦学学报,2000;20(6):478480
[15]王勋成,邵敏.有限单元法基本原理和数值方法.清华大学出版社,1997
[16]刘棣华.粘弹阻尼减振降噪应用技术.宇航出版社,1990:37-40
[17]李以农,郑玲,曾励.汽车制动噪声研究状况及存在的问题.汽车研究与开发,1994,3:36-38
[18]董其伍,刘启玉.CAE技术回顾与展望.计算机工程与应用,2002(14):82-84
[19]张铁山.车架设计中CAD/CAE技术及应用.机械设计与制造,2002(2):33-37
[20]管迪华.模态分析技术.北京清华大学出版社,1996
[21]李德葆,陆秋海.实验模态分析及其应用.北京科学出版社,2001
[22]胡宗武.工程振动分析基础.上海交通大学出版社,1985
[23]陈晓霞等.ANSYS7.0高级分析.机械工业出版社,2004
[24]吴剑增.汽车制动噪声产生的原因及影响.汽车与环保,1994,3:25-30
[25]NackWV.Brake squeal analysis by finite elements.SAE1999-01-1736,1996
[26]刘惟信.汽车制动系的结构分析与设计计算.清华大学出版社,2004:80-81
[27]方泳龙.汽车制动理论与设计.国防工业出版社,2005
[28]管迪华.模态分析技术.清华大学出版社,1996
[29]任重.ANSYS实用分析教程.北京:北京大学出版社,2003.2;
[30]吴家龙.弹性力学.高等教育出版社,2002
[31]方泳龙.汽车制动理论与设计.国防工业出版社,2005
[32]靳晓雄等.汽车振动分析.同济大学出版社,2002
[33]贾宏禹,黄之初.材料的粘弹性对摩擦片振动与制动噪声的影响研究.武汉理工大学硕士学位论文,2003.5
[34]潘公宇.盘式制动器的特点及其应用.试验与研究,1996(2):29-32;
[35]许尚贤.机械设计中的有限元法.高等教育出版社,1992.7;
[36]徐兀.汽车振动和噪声控制.北京:北京人民交通出版社,2001,25-35;
[37]贾宏禹,曹献坤,黄之初等.关于粘弹性盘式制动器摩擦片的模态分析.武汉理工大学学报.2003.9
[38]管仁梅.大客车鼓式制动器的多柔体ADAMS建模.吉林大学硕士学位论文,2004
[39]王涛,朱文坚.摩擦制动器-原理、结构与设计.华南理工大学出版社,1992
[40]谢卫国.鼓式制动器噪声试验研究.长春:吉林工业大学,1988
[41]何宇平.国内外汽车制动法规评述及制动性能分析.北京:清华大学,1991
[42]Lee K,et al.Conditions of frictional contact in disk brakes and their effects on brake judder.SAE980598,1998
[43]KusanoM,et al.Expedmental study on the reduction of drum brake noise.SAE851465,1985
[44]Matsui H,Murakami H,etc.Analysis of disk brake squeal.SAE920553,1992
[45]Shih-Wei Kung,K.Brent Dunlap,Robert S.Ballinger.Complex eigenvalue analysis.2005
[46]方宇飞,孙茂.叶轮机械的气动数值优化方法.北京航天航空大学博士后学位论文,2004
[47]左鹤声,彭玉莺.振动试验模态分析.北京:中国铁道出版社,1995
[48]李建华,孙传学.应用有限元法降低制动噪声的研究.吉林大学硕士学位论文,2006
[2]庞剑,谌刚,何华.汽车噪声与振动理论与应用.北京:北京理工大学出版社,2006:15
[3]李以农,郑玲,曾励.汽车制动噪声研究状况及存在的问题.北京:北京理工大学出版社,1994,3:36-38
[4]吴剑增.汽车制动噪声产生的原因及影响.汽车与环保,1994,3:25-30
[5]Coonki Park,Min Gyu Han,Sung Sun Choetal.A Study on the Reduction of the DiskBrake Squeal Using Complex Eigenvalue Analysis.SAE2001-01-3141,2001
[6]管迪华,宿新东.制动振动噪声研究的回顾、发展与评述.工程力学,2004,8:150-155
[7]RheeS K,et al.The role of friction film in friction,wear and noise of automotive brakes.Wear 1991,146:89-97
[8]Millner N.An analysis of disc brake squeal.SAE780332,1978
[9]SinelairD,ManwillNJ.FrictionVibratlon..APP.meeh.,1955(22)
[10]黄士振.有限元法.南京:南京理工大学,1986
[11]Spurr R T.Brake squeal.l Mech E,1971,95/71:13-15
[12]Millner N.A theory of drum brake squeal.I Mech E,1976,c39/76:10-185
[13]陈世雄,鼓式制动器制动尖叫的研究.中国优秀硕士学位论文全文数据库:清华大学,1988
[14]陈光雄,周仲荣,谢友柏.摩擦噪声研究的现状和进展.摩擦学学报,2000;20(6):478480
[15]王勋成,邵敏.有限单元法基本原理和数值方法.清华大学出版社,1997
[16]刘棣华.粘弹阻尼减振降噪应用技术.宇航出版社,1990:37-40
[17]李以农,郑玲,曾励.汽车制动噪声研究状况及存在的问题.汽车研究与开发,1994,3:36-38
[18]董其伍,刘启玉.CAE技术回顾与展望.计算机工程与应用,2002(14):82-84
[19]张铁山.车架设计中CAD/CAE技术及应用.机械设计与制造,2002(2):33-37
[20]管迪华.模态分析技术.北京清华大学出版社,1996
[21]李德葆,陆秋海.实验模态分析及其应用.北京科学出版社,2001
[22]胡宗武.工程振动分析基础.上海交通大学出版社,1985
[23]陈晓霞等.ANSYS7.0高级分析.机械工业出版社,2004
[24]吴剑增.汽车制动噪声产生的原因及影响.汽车与环保,1994,3:25-30
[25]NackWV.Brake squeal analysis by finite elements.SAE1999-01-1736,1996
[26]刘惟信.汽车制动系的结构分析与设计计算.清华大学出版社,2004:80-81
[27]方泳龙.汽车制动理论与设计.国防工业出版社,2005
[28]管迪华.模态分析技术.清华大学出版社,1996
[29]任重.ANSYS实用分析教程.北京:北京大学出版社,2003.2;
[30]吴家龙.弹性力学.高等教育出版社,2002
[31]方泳龙.汽车制动理论与设计.国防工业出版社,2005
[32]靳晓雄等.汽车振动分析.同济大学出版社,2002
[33]贾宏禹,黄之初.材料的粘弹性对摩擦片振动与制动噪声的影响研究.武汉理工大学硕士学位论文,2003.5
[34]潘公宇.盘式制动器的特点及其应用.试验与研究,1996(2):29-32;
[35]许尚贤.机械设计中的有限元法.高等教育出版社,1992.7;
[36]徐兀.汽车振动和噪声控制.北京:北京人民交通出版社,2001,25-35;
[37]贾宏禹,曹献坤,黄之初等.关于粘弹性盘式制动器摩擦片的模态分析.武汉理工大学学报.2003.9
[38]管仁梅.大客车鼓式制动器的多柔体ADAMS建模.吉林大学硕士学位论文,2004
[39]王涛,朱文坚.摩擦制动器-原理、结构与设计.华南理工大学出版社,1992
[40]谢卫国.鼓式制动器噪声试验研究.长春:吉林工业大学,1988
[41]何宇平.国内外汽车制动法规评述及制动性能分析.北京:清华大学,1991
[42]Lee K,et al.Conditions of frictional contact in disk brakes and their effects on brake judder.SAE980598,1998
[43]KusanoM,et al.Expedmental study on the reduction of drum brake noise.SAE851465,1985
[44]Matsui H,Murakami H,etc.Analysis of disk brake squeal.SAE920553,1992
[45]Shih-Wei Kung,K.Brent Dunlap,Robert S.Ballinger.Complex eigenvalue analysis.2005
[46]方宇飞,孙茂.叶轮机械的气动数值优化方法.北京航天航空大学博士后学位论文,2004
[47]左鹤声,彭玉莺.振动试验模态分析.北京:中国铁道出版社,1995
[48]李建华,孙传学.应用有限元法降低制动噪声的研究.吉林大学硕士学位论文,2006