Mechanism research and structure optimization of brake noise based on contact overlap degree

Brake noise can endanger the psychological and physiological health of passengers, as well as cause noise pollution. Therefore, it is important to suppress the noise from the design stage of the braking system. Based on the establishment of a complex modal finite element model of the brake and verification of the validity of the model through bench test, the mechanism of “contact overlap degree” is proposed, that is, the influence of the brake disc-block friction contact overlap degree on the brake noise. In order to better simulate the real situation during brake friction contact, a face-spring distributed contact model of the brake is developed and the key influencing factors of contact overlap degree are selected. Based on the asymmetry and unevenness of contact overlap degree distribution, the structural optimization schemes of brake backplane and friction lining are proposed respectively, and the complex modal analysis is re-performed. The analysis results show that the noise incidence is reduced after structural optimization, which verifies the effectiveness of the above two structural optimization schemes in reducing brake noise.