基于虚拟样机的轿车盘式制动器制动尖叫的研究
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摘要
在21世纪的今天,汽车已经成为了人们生活中必不可少的交通工具之一,汽车的普及让人们的生活质量得到了进一步的提高,然而随着汽车的普及,伴随便捷生活而来的还有一系列的问题,其中对环境的噪声污染就是一个函待解决的重大问题。
本文以某轿车盘式制动器实物为原型,以振动理论为基础,以三维设计软件CATIA V5 R17、数据快速自动交换专用软件CADFIX 7.1和有限元分析软件ANSYS9.0为工具,针对该制动器在一些工况时易产生制动尖叫的问题,对该制动器在结构参数方面进行优化。
本文首先运用三维设计软件CATIA V5 R17的机械零部件设计(PDG:Part Design)和装配设计(ASD:Assembly Design)模块,结合自底向上(BOTTUM-UP)和自顶向下(TOP-DOWN)两种建模方法对盘式制动器进行建模,然后运用运动机构模拟(KIN:DMU Kinematics)模块对模型进行模拟仿真,在确定模型各个零部件结构尺寸合理、总成仿真运动良好后再对各个零部件进行简化,删除对有限元分析精度影响不大但对计算量却影响极大的倒角、小孔等结构元素,为下一步的有限元分析做好准备,然后用数据快速自动交换专用软件CADFIX 7.1将在CATIA V5 R17中建好的,以*modle格式保存的盘式制动器各个零部件模型转换成Prosolid 14.0的格式,使建好的三维模型转化成能导入ANSYS9.0的文件格式。把模型导入ANSYS9.0后,根据查找到的盘式制动器各个零部件的材料属性和历史试验数据,对盘式制动器进行有限元建模,在完成单元选择、网格划分、边界条件约束和计算频率范围的设置后,采用Block Lanczos(分块)法对模型进行模态分析,确定结构的固有频率和振型,从结构参数上找出易产生制动尖叫的零部件,再用CATIA V5 R17对结构设计不合理的零部件在结构上进行优化设计,然后对优化设计后的零部件再次进行模态分析,如此循环工作,直到确定振型得到改善。
本次研究表明,通过改进结构的方法能有效改善盘式制动器结构振幅、振速从而抑制制动尖叫的发生。
In the 21st century, cars have become an indispensable means of transport of people's lives, one of the popular vehicles to people's quality of life has been further improved, but with the popularity of the car, also comes with convenient life a series of issues, including environmental noise pollution is a major issue to be addressed letter.
Based on a physical prototype car disc brake, the vibration theory, three-dimensional design software, CATIA V5 R17, fast automatic exchange of data-specific software CADFIX 7.1 and the finite element analysis software ANSYS9.0 as a tool for the brake in some work situation when the problem is easy to produce brake squeal, the brake to optimize the structure parameters.
Firstly, the use of 3D design software for CATIA V5 R17 Design of mechanical parts (PDG:Part Design), and assembly design (ASD:Assembly Design) modules, combined with bottom-up (BOTTUM-UP) and top-down (TOP-DOWN) two modeling methods to model disc brake, and then use movement mechanism simulation (KIN:DMU Kinematics) module of the model simulation, various components in determining the model structure of reasonable size, well after the assembly of each simulation exercise components can be simplified to remove the finite element analysis of accuracy of calculation is small but great influence on the chamfer, holes and other structural elements, the finite element analysis for the next step to prepare, and then fast automatic exchange of private data CADFIX 7.1 software will be built in CATIA V5 R17 in the order* modle format of the disc brake model into various parts Prosolid 14.0 format, so that the three-dimensional model built into the file format can be imported ANSYS9.0. After the model into ANSYS9.0, find the disc brake according to the various parts of the material properties and historical test data, finite element modeling of disc brakes, the completion of unit selection, meshing, boundary conditions and calculation of binding frequency range of settings, using Block Lanczos (block) method of the model modal analysis to determine the structure of the natural frequencies and mode shapes, from the structural parameters to identify the parts easy to produce brake squeal, and then CATIA V5 R17 irrational parts of the structural design of the structure is optimized, and then parts of the optimum design of modal analysis again, this cycle of work, until you determine the mode to improve.
This study shows that by improving the structure of the method can effectively improve the disc brake structure of the amplitude of velocity to suppress the occurrence of brake squeal.
本文以某轿车盘式制动器实物为原型,以振动理论为基础,以三维设计软件CATIA V5 R17、数据快速自动交换专用软件CADFIX 7.1和有限元分析软件ANSYS9.0为工具,针对该制动器在一些工况时易产生制动尖叫的问题,对该制动器在结构参数方面进行优化。
本文首先运用三维设计软件CATIA V5 R17的机械零部件设计(PDG:Part Design)和装配设计(ASD:Assembly Design)模块,结合自底向上(BOTTUM-UP)和自顶向下(TOP-DOWN)两种建模方法对盘式制动器进行建模,然后运用运动机构模拟(KIN:DMU Kinematics)模块对模型进行模拟仿真,在确定模型各个零部件结构尺寸合理、总成仿真运动良好后再对各个零部件进行简化,删除对有限元分析精度影响不大但对计算量却影响极大的倒角、小孔等结构元素,为下一步的有限元分析做好准备,然后用数据快速自动交换专用软件CADFIX 7.1将在CATIA V5 R17中建好的,以*modle格式保存的盘式制动器各个零部件模型转换成Prosolid 14.0的格式,使建好的三维模型转化成能导入ANSYS9.0的文件格式。把模型导入ANSYS9.0后,根据查找到的盘式制动器各个零部件的材料属性和历史试验数据,对盘式制动器进行有限元建模,在完成单元选择、网格划分、边界条件约束和计算频率范围的设置后,采用Block Lanczos(分块)法对模型进行模态分析,确定结构的固有频率和振型,从结构参数上找出易产生制动尖叫的零部件,再用CATIA V5 R17对结构设计不合理的零部件在结构上进行优化设计,然后对优化设计后的零部件再次进行模态分析,如此循环工作,直到确定振型得到改善。
本次研究表明,通过改进结构的方法能有效改善盘式制动器结构振幅、振速从而抑制制动尖叫的发生。
In the 21st century, cars have become an indispensable means of transport of people's lives, one of the popular vehicles to people's quality of life has been further improved, but with the popularity of the car, also comes with convenient life a series of issues, including environmental noise pollution is a major issue to be addressed letter.
Based on a physical prototype car disc brake, the vibration theory, three-dimensional design software, CATIA V5 R17, fast automatic exchange of data-specific software CADFIX 7.1 and the finite element analysis software ANSYS9.0 as a tool for the brake in some work situation when the problem is easy to produce brake squeal, the brake to optimize the structure parameters.
Firstly, the use of 3D design software for CATIA V5 R17 Design of mechanical parts (PDG:Part Design), and assembly design (ASD:Assembly Design) modules, combined with bottom-up (BOTTUM-UP) and top-down (TOP-DOWN) two modeling methods to model disc brake, and then use movement mechanism simulation (KIN:DMU Kinematics) module of the model simulation, various components in determining the model structure of reasonable size, well after the assembly of each simulation exercise components can be simplified to remove the finite element analysis of accuracy of calculation is small but great influence on the chamfer, holes and other structural elements, the finite element analysis for the next step to prepare, and then fast automatic exchange of private data CADFIX 7.1 software will be built in CATIA V5 R17 in the order* modle format of the disc brake model into various parts Prosolid 14.0 format, so that the three-dimensional model built into the file format can be imported ANSYS9.0. After the model into ANSYS9.0, find the disc brake according to the various parts of the material properties and historical test data, finite element modeling of disc brakes, the completion of unit selection, meshing, boundary conditions and calculation of binding frequency range of settings, using Block Lanczos (block) method of the model modal analysis to determine the structure of the natural frequencies and mode shapes, from the structural parameters to identify the parts easy to produce brake squeal, and then CATIA V5 R17 irrational parts of the structural design of the structure is optimized, and then parts of the optimum design of modal analysis again, this cycle of work, until you determine the mode to improve.
This study shows that by improving the structure of the method can effectively improve the disc brake structure of the amplitude of velocity to suppress the occurrence of brake squeal.
引文
[1]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
[2]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,1992.12
[3]JohnD.Fieldhouse, A proPosal to Prediet the Noise Frequency of a Disc Brake Based on the Friction Pair Interface Geometry, SAE,1999-01-3403
[4]Harald Abendroth, Uwe Schwarz, Coerrlating Dynamometer and Vehiele Brake Test Results
[5]Kiran.Krishnapur, Aaorn Lock,Brake Rattle:Vibartion and Noise Testing, SAE,2002-01-2608
[6]Rajesh J.Somnay, Shan Shih,Predicting Durm Brake Noise Using Finite Element Methods, SAE,2002-01-3139
[7]Yu-Kan Hu, Sanjay K. Mahajan, Barke Squeal Doe Using Nonlinear Transient Analysis, SAE, 1999-01-1737
[8]陈家瑞,汽车构造(下).北京：人民交通出版社,1999
[9]机械工程手册.3：工程材料卷.北京：机械工业出版社,1999
[10]潘公宇.盘式制动器的特点及其应用.试验与研究,1996(2)：29-32
[11]Kenneth A.Cunefare,Investigation of Disc Brake Squeal Via Sound Intensity and Laser Vibrometry, SAE,2001-01-1604
[12]渝可生.汽车噪声控制.北京：机械工业出版社,1995
[13]RieadroCanali, Alber to Tamanga, Evaluation of PorPerties of Disc and Pad Materials and Their Relation With Disc Brake Noise An EXPerimental Investigation, SAE,2002-01-2604
[14]卢耀祖.机械与汽车结构的有限元分析.同济大学出版社,1997
[15]管迪华.模态分析技术.清华大学出版社,1996
[16]任重.ANSYS实用分析教程,北京：北京大学出版社,2003.2
[17]许尚贤.机械设计中的有限元法.高等教育出版社,1997.2
[18]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.Vol(25)No.9
[19]田洪涛.基于ANSYS的盘式制动器振动噪声分析与研究：[硕士学位论文],武汉：武汉理工大学机电工程学院,2009
[20]叶先磊,史亚杰.ANSYS工程分析软件应用与实例.清华大学出版社,2004年4月
[21]ANSYS LS-DYNA动力分析方法与工程实例.中国水利水电出版社,2005
[22]田志宇.钳盘式制动器制动噪声分析与控制：[硕士学位论文],吉林：吉林大学车辆工程,2008
[23]JohnD.Fieldhouse, ChrisJohn Talbot,Invesrigation of Durm Brake Noise Froma Brake Mountedona Half Vehicle Test rig, SAE,2002-01-2613
[24]TstevenShi, W.K.Chang,Advances in ComPlex Eigenvalue Analysis of Breake Noise, SAE, 2001-01-1603
[25]HemranD.Vander Auweraer, William Hendricx, Experimental and Numerical Modelling Of Friction-Indueed Noise in Dise Brkaes, SAE,2002-01-1192
[26]美ISaedeMoaveni,欧阳宇等译.有限元分析-ANSYS理论与应用.电子工业出版社,2003.6
[27]唐旭冕.盘式制动器结构非线性分析与计算：[硕士学位论文],福州大学机械设计及理论,2003
[28]任仲贵.CAD/CAM原理.北京：清华大学出版社,1991
[29]张洪武,关振群,李云鹏等.有限元分析与CAE技术基础.清华大学出版社,2004
[30]倪栋,段进,徐久成等.通用有限元分析ANSYS.70实例精解.电子工业出版社,2003.10
[31]蒋东鹰.制动器尖叫问题研究方法初探：[硕士学位论文].清华大学汽车学院,1995
[32]陈宏伟,宋健等.盘式制动器摩擦特性的指数函数模型.农业机械学报,2002.09
[33]曾正明主编.机械工程材料手册.金属篇第6版.机械工业出版社,2003.1
[34]韩秋实.汽车刹车装置摩擦噪声的试验研究.声学技术,1998.17(3)：117-122
[35]孙振华,曾庆华,蒋东鹰等.盘式制动器制动尖叫的研究.汽车工程,1999(vol.21)No.6
[36]黄新建.盘式制动器制动尖叫影响因素分析：[硕士学位论文].吉林：吉林大学车辆工程,2008
[37]李清,刘佐明,蔡萼华.浮钳盘式制动器结构稳定性仿真分析.武汉理工大学学报,2008.05-0744-05
[38]武素容,奚乐.汽车制动器系统压力容积模拟计算.上海汽车,2007.02
[39]李思昆等.协作虚拟样机与协同设计方法.系统仿真学报,2001.1.
[40]张滨刚,姜正根.汽车制动过程的理论分析与试验.兵工学报,1998.4
[41]王国强,张进平,马若丁.虚拟样机技术及其在ADAMS上的实践.西北工业大学出版社,2002年3月
[42]鸦尽勇.虚拟样机技术在机构精度分析中的研究与应用：[硕士学位论文].长沙,湖南大学机电学院,2004年4月
[43]张芳,管迪华.抑制制动器振动噪声的阻尼方法的探讨.汽车工程,2003(vol25)N.o3
[44]管仁梅.大客车鼓式制动器的多柔体ADAMS建模：[硕士学位论文].吉林大学,2004.5
[45]李长春.CATIA V5P3R17应用与实例教程.中国电力出版社,2008
[46]盛选禹,盛选军.CATIA V5运动和力学分析实例教程.化学工业出版社,2008
[47]王朝阳.汽车盘式制动器尖叫倾向性分析与设计改进：[硕士学位论文].上海：上海交通大学机械与动力工程,2008
[48]贾宏禹.材料的粘弹性对摩擦片振动与制动噪声的影响研究：[硕士学位论文].武汉：武汉理工大学机电工程学院,2003.5
[49]郑家杰,孟春玲,张力.汽车制动控制系统的技术进展.北京工商大学学报,2005.23(5)
[50]蒋东鹰,管迪华.盘式制动器制动尖叫计算模型的建立.汽车技术,1997年第7期
[51]宁晓斌,张文明等.用虚拟样机技术分析鼓式制动器的振动.有色金属,2003年5月,第55卷第2期
[52]方远乔.振动模态分析技术.北京：国防工业出版社,1993
[53]傅志方.振动模态分析与参数辨别.北京：机械工业出版社,1990
[54]中国汽车技术研究中心汽车标准研究所《汽车设计标准资料手册：标准件篇》.长春：吉林科学技术出版社,2000
[2]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,1992.12
[3]JohnD.Fieldhouse, A proPosal to Prediet the Noise Frequency of a Disc Brake Based on the Friction Pair Interface Geometry, SAE,1999-01-3403
[4]Harald Abendroth, Uwe Schwarz, Coerrlating Dynamometer and Vehiele Brake Test Results
[5]Kiran.Krishnapur, Aaorn Lock,Brake Rattle:Vibartion and Noise Testing, SAE,2002-01-2608
[6]Rajesh J.Somnay, Shan Shih,Predicting Durm Brake Noise Using Finite Element Methods, SAE,2002-01-3139
[7]Yu-Kan Hu, Sanjay K. Mahajan, Barke Squeal Doe Using Nonlinear Transient Analysis, SAE, 1999-01-1737
[8]陈家瑞,汽车构造(下).北京：人民交通出版社,1999
[9]机械工程手册.3：工程材料卷.北京：机械工业出版社,1999
[10]潘公宇.盘式制动器的特点及其应用.试验与研究,1996(2)：29-32
[11]Kenneth A.Cunefare,Investigation of Disc Brake Squeal Via Sound Intensity and Laser Vibrometry, SAE,2001-01-1604
[12]渝可生.汽车噪声控制.北京：机械工业出版社,1995
[13]RieadroCanali, Alber to Tamanga, Evaluation of PorPerties of Disc and Pad Materials and Their Relation With Disc Brake Noise An EXPerimental Investigation, SAE,2002-01-2604
[14]卢耀祖.机械与汽车结构的有限元分析.同济大学出版社,1997
[15]管迪华.模态分析技术.清华大学出版社,1996
[16]任重.ANSYS实用分析教程,北京：北京大学出版社,2003.2
[17]许尚贤.机械设计中的有限元法.高等教育出版社,1997.2
[18]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.Vol(25)No.9
[19]田洪涛.基于ANSYS的盘式制动器振动噪声分析与研究：[硕士学位论文],武汉：武汉理工大学机电工程学院,2009
[20]叶先磊,史亚杰.ANSYS工程分析软件应用与实例.清华大学出版社,2004年4月
[21]ANSYS LS-DYNA动力分析方法与工程实例.中国水利水电出版社,2005
[22]田志宇.钳盘式制动器制动噪声分析与控制：[硕士学位论文],吉林：吉林大学车辆工程,2008
[23]JohnD.Fieldhouse, ChrisJohn Talbot,Invesrigation of Durm Brake Noise Froma Brake Mountedona Half Vehicle Test rig, SAE,2002-01-2613
[24]TstevenShi, W.K.Chang,Advances in ComPlex Eigenvalue Analysis of Breake Noise, SAE, 2001-01-1603
[25]HemranD.Vander Auweraer, William Hendricx, Experimental and Numerical Modelling Of Friction-Indueed Noise in Dise Brkaes, SAE,2002-01-1192
[26]美ISaedeMoaveni,欧阳宇等译.有限元分析-ANSYS理论与应用.电子工业出版社,2003.6
[27]唐旭冕.盘式制动器结构非线性分析与计算：[硕士学位论文],福州大学机械设计及理论,2003
[28]任仲贵.CAD/CAM原理.北京：清华大学出版社,1991
[29]张洪武,关振群,李云鹏等.有限元分析与CAE技术基础.清华大学出版社,2004
[30]倪栋,段进,徐久成等.通用有限元分析ANSYS.70实例精解.电子工业出版社,2003.10
[31]蒋东鹰.制动器尖叫问题研究方法初探：[硕士学位论文].清华大学汽车学院,1995
[32]陈宏伟,宋健等.盘式制动器摩擦特性的指数函数模型.农业机械学报,2002.09
[33]曾正明主编.机械工程材料手册.金属篇第6版.机械工业出版社,2003.1
[34]韩秋实.汽车刹车装置摩擦噪声的试验研究.声学技术,1998.17(3)：117-122
[35]孙振华,曾庆华,蒋东鹰等.盘式制动器制动尖叫的研究.汽车工程,1999(vol.21)No.6
[36]黄新建.盘式制动器制动尖叫影响因素分析：[硕士学位论文].吉林：吉林大学车辆工程,2008
[37]李清,刘佐明,蔡萼华.浮钳盘式制动器结构稳定性仿真分析.武汉理工大学学报,2008.05-0744-05
[38]武素容,奚乐.汽车制动器系统压力容积模拟计算.上海汽车,2007.02
[39]李思昆等.协作虚拟样机与协同设计方法.系统仿真学报,2001.1.
[40]张滨刚,姜正根.汽车制动过程的理论分析与试验.兵工学报,1998.4
[41]王国强,张进平,马若丁.虚拟样机技术及其在ADAMS上的实践.西北工业大学出版社,2002年3月
[42]鸦尽勇.虚拟样机技术在机构精度分析中的研究与应用：[硕士学位论文].长沙,湖南大学机电学院,2004年4月
[43]张芳,管迪华.抑制制动器振动噪声的阻尼方法的探讨.汽车工程,2003(vol25)N.o3
[44]管仁梅.大客车鼓式制动器的多柔体ADAMS建模：[硕士学位论文].吉林大学,2004.5
[45]李长春.CATIA V5P3R17应用与实例教程.中国电力出版社,2008
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