2 dissatisfaction on the quality of noise produced from the brake Crolla and lang,
1991. Customer might file a warranty claim despite that the brake disc is still functioning very well.
Modal analysis is one of the methods used by many researchers to understand the brake squeal phenomenon. Modal analysis work will represent the mode shape and
natural frequencies of the brake disc. There are three general categories of noise associated with automotive disc
brakes. These categories are classified according to the frequency range in which the noise occurs. Low frequency disc brake noise typically occurs in the frequency range
between 100 and 1000 Hz Kinkaid et al., 2003. The noise types in this category are known as grunt, groan, grind and moan Papinniemi et al., 2002. These are caused
by friction material excitation at the brake rotor and lining interface where the energy is transmitted as a vibration within the wheel corner which couples with other chassis
components Dunlap et al., 1999. For the frequency bandwidth 1000 Hz to 5 kHz, the noise generated is classified as low frequency squeal Dunlap et al., 1999. High
frequency squeal is classified as squeal occurring above 5 kHz Crolla and Lang, 1991. Squeal noise is produced by friction induced excitation, causing coupled
resonance between the rotor and other brake components North, 1972.
1.1 Problem statement
This project is about to investigate the brake squeal phenomenon using finite element analysis FEA. By understanding the vibration characteristics and mode
classification of the solid disc brake type, it will be a useful tool to assist brake disc designers for necessary modifications of existing disc brake structure to enhanced
brake disc behaviour to avoid brake squeal. The FEA software is used to analyse the behaviour of the brake disc rotor. Modal
properties, natural frequencies and mode shape of disc rotor can be obtained through FE model prediction using ABAQUS. From existing geometry of FV racing car
brake disc rotor, The 3D model is also can be created using ABAQUS software. The study on five different types of material properties is carried out to shows the effect
3 of vibration mode and natural frequency as the cause of brake squeal happened. The
second part of this project is to classify the frequencies obtained from free – free modal analysis into three categories low frequency brake noise, high frequency brake
squeal, and low frequency brake squeal.
1.2 Aim and Objective of Research
1.2.1 Aim
The overall aim of this research is to investigate the brake squeal phenomenon at early stage prediction that happened since the past decades. To achieve the
mentioned objectives, a Formula Varsity disc brake rotor will be used in this project to be carried out modeling simulation. Selection of disc brake materials based on its
properties will be used to investigate in order to determine the effect of vibration that causing the brake squeal. Finite Element Analysis approach will be performed to
identify the squeal noise problem. This will verify on how the brake squeal phenomenon occurs.
1.2.2 Objective
Based on the problem statement, the objectives have been drawn: I.
To study on brake squeal phenomenon on five different types of material. II.
To analyse the effect of vibration in term of brake disc rotor behaviour. III.
To classify the natural frequencies in 3 different categories.
4
1.3 Scope and Limitation of The Project
