The main objective of this research is to address the relationship between formulation of friction lining materials and their propensity to friction induced noise generation. The basic idea was formulated earlier by Dr. Filip, who showed that the friction layer plays the relevant role when noise is observed during braking. It was shown that when newly formed patches (parts of the friction layer) exhibit a large difference in the coefficient of friction, brake lining is stretched and released repeatedly, which leads to significant vibrations and corresponding noise when coupled with the vibration mode of the system. Farhang ,on the other hand, demonstrated that noise can be related to specific surface roughness parameters and when properties of friction lining and friction layer (such as compressibility, stiffness and modulus of elasticity) fit into certain specific value ranges, noisy behavior occurs. This research will address the braking related to friction induced noise in relation to the properties of the bulk lining material and the character and properties of the friction layer. The friction tests will be performed using the CAFS-developed (Szary and Lee) real time noise measurement system compatible with the major part of SAEJ2521 standard (note that the system does not allow for reliable measurement of frequencies lower than 900 Hz). The mechanical properties of fourteen samples will be investigated. Of the fourteen samples, friction layer of three of the samples will be investigated by several analytical techniques developed by Dr. Filip [1]. They include polarized light microscopy, scanning and transmission electron microscopy equipped with energy dispersive microanalysis, and X-ray diffraction. This research summarizes data from the J2521 dynamometer test of the Dodge Caravan samples exhibiting specific compressibility, porosity and hardness. Also, this research provides the results of friction surface analysis by SEM with energy dispersive microanalysis, light microscopy, surface roughness, and X ray diffraction. Of the fourteen samples, Bendix has the largest occurrence of noisy braking. Based on techniques developed by Dr. Filip, the characteristics of the friction layer strongly influence brake noise propensity. The friction layer characteristics are dependent on brake formulation. As predicted, "noisy stop" and "quiet stop" samples exhibit completely different friction surfaces.

Sistemas de freio automotivos são frequentemente suscetíveis a gerarem ruídos de alta frequência como resultado de uma vibração autoexcitada. Este fenômeno é genericamente nominado squeal noise e constitui o tema de diversos estudos publicados com o intuito de identificar e descrever seu mecanismo de excitação e de propor alternativas para evitar sua ocorrência. Um ponto fundamental que ainda não foi completamente explorado sobre a geração de tal fenômeno constitui-se da relação entre as propriedades do material de fricção e a propensão à ocorrência de squeal noise. Este trabalho apresenta o desenvolvimento de um número adimensional obtido através de análise dimensional (teorema de Buckingham) capaz de relacionar a ocorrência de squeal noise as quatro principais propriedades dos compósitos de fricção: dureza, tamanho de partícula e concentração do abrasivo utilizado na formulação, além de sua compressibilidade. Resultados experimentais foram obtidos a partir de ensaios desenvolvidos com seis diferentes materiais de fricção nos quais a concentração ou dureza ou tamanho de partícula foi alterada de modo a oportunizar a identificação do impacto destas variáveis sobre a ocorrência de squeal noise. A ocorrência de ruídos foi verificada através da aplicação de um método de ensaio em dinamômetro inercial especialmente desenvolvido a um conjunto de amostras dos materiais de fricção moldados a pastilhas de freio e aplicados a um sistema de freio a disco convencional. Os resultados obtidos validaram o número adimensional proposto (índice de excitação 2) na medida em que foi possível estabelecer sua relação com a ocorrência de ruídos verificada experimentalmente através de uma equação logarítmica (R²=0,9). Foi estabelecida também uma relação entre o aumento do coeficiente de atrito, em função da redução da velocidade de escorregamento, e o aumento da ocorrência de squeals. Uma breve investigação a respeito da relevância da rigidez de contato sobre o comportamento vibroacústico do sistema de freio também é conduzida, tendo sido demonstrado que o aumento da magnitude desta propriedade reduz a ocorrência de ruídos do tipo squeal. / Automotive brake systems are very often susceptible to generate high frequency noise as a result of a self excited vibration. This phenomenon is generically nominated brake squeal noise and is the subject of many studies which intend to identify and describe its exciting mechanism and to propose counter measures to avoid its occurrence. One key subject yet to be explored about squeal noise generation is the relation between friction material properties and its occurrence propensity. This work presents the development of an adimentional number obtained by dimensional analysis (Buckingham theorem) capable to relate the squeal noise occurrence with four main properties from the friction composite: abrasive hardness, particle size and concentration and also its compressibility. Experimental results were obtained by testing six different friction material formulations, in which the concentration of abrasive or its hardness or its particle size was altered in order to explore the impact of these variables on the squeal noise occurrence. The noise generation was accessed by testing the friction materials molded to brake pads using a standard disc brake system in an inertial dynamometer under a specially developed test procedure. The obtained results validated the proposed adimentional number (excitation index 2) since was possible to establish a logarithmic equation (R²=0,9) relating it to the squeal noise occurrence verified on the conduced tests. It was also established a relation between the friction coefficient increase, as a function of the sliding speed reduction, with the increase on squeal noise occurrence. A brief investigation about the relevance of the contact stiffness to the vibroacustic behavior of the brake systems was developed, showing that higher values of this property can reduce the squeal noise generation.

Sistemas de freio automotivos são frequentemente suscetíveis a gerarem ruídos de alta frequência como resultado de uma vibração autoexcitada. Este fenômeno é genericamente nominado squeal noise e constitui o tema de diversos estudos publicados com o intuito de identificar e descrever seu mecanismo de excitação e de propor alternativas para evitar sua ocorrência. Um ponto fundamental que ainda não foi completamente explorado sobre a geração de tal fenômeno constitui-se da relação entre as propriedades do material de fricção e a propensão à ocorrência de squeal noise. Este trabalho apresenta o desenvolvimento de um número adimensional obtido através de análise dimensional (teorema de Buckingham) capaz de relacionar a ocorrência de squeal noise as quatro principais propriedades dos compósitos de fricção: dureza, tamanho de partícula e concentração do abrasivo utilizado na formulação, além de sua compressibilidade. Resultados experimentais foram obtidos a partir de ensaios desenvolvidos com seis diferentes materiais de fricção nos quais a concentração ou dureza ou tamanho de partícula foi alterada de modo a oportunizar a identificação do impacto destas variáveis sobre a ocorrência de squeal noise. A ocorrência de ruídos foi verificada através da aplicação de um método de ensaio em dinamômetro inercial especialmente desenvolvido a um conjunto de amostras dos materiais de fricção moldados a pastilhas de freio e aplicados a um sistema de freio a disco convencional. Os resultados obtidos validaram o número adimensional proposto (índice de excitação 2) na medida em que foi possível estabelecer sua relação com a ocorrência de ruídos verificada experimentalmente através de uma equação logarítmica (R²=0,9). Foi estabelecida também uma relação entre o aumento do coeficiente de atrito, em função da redução da velocidade de escorregamento, e o aumento da ocorrência de squeals. Uma breve investigação a respeito da relevância da rigidez de contato sobre o comportamento vibroacústico do sistema de freio também é conduzida, tendo sido demonstrado que o aumento da magnitude desta propriedade reduz a ocorrência de ruídos do tipo squeal. / Automotive brake systems are very often susceptible to generate high frequency noise as a result of a self excited vibration. This phenomenon is generically nominated brake squeal noise and is the subject of many studies which intend to identify and describe its exciting mechanism and to propose counter measures to avoid its occurrence. One key subject yet to be explored about squeal noise generation is the relation between friction material properties and its occurrence propensity. This work presents the development of an adimentional number obtained by dimensional analysis (Buckingham theorem) capable to relate the squeal noise occurrence with four main properties from the friction composite: abrasive hardness, particle size and concentration and also its compressibility. Experimental results were obtained by testing six different friction material formulations, in which the concentration of abrasive or its hardness or its particle size was altered in order to explore the impact of these variables on the squeal noise occurrence. The noise generation was accessed by testing the friction materials molded to brake pads using a standard disc brake system in an inertial dynamometer under a specially developed test procedure. The obtained results validated the proposed adimentional number (excitation index 2) since was possible to establish a logarithmic equation (R²=0,9) relating it to the squeal noise occurrence verified on the conduced tests. It was also established a relation between the friction coefficient increase, as a function of the sliding speed reduction, with the increase on squeal noise occurrence. A brief investigation about the relevance of the contact stiffness to the vibroacustic behavior of the brake systems was developed, showing that higher values of this property can reduce the squeal noise generation.

Sistemas de freio automotivos são frequentemente suscetíveis a gerarem ruídos de alta frequência como resultado de uma vibração autoexcitada. Este fenômeno é genericamente nominado squeal noise e constitui o tema de diversos estudos publicados com o intuito de identificar e descrever seu mecanismo de excitação e de propor alternativas para evitar sua ocorrência. Um ponto fundamental que ainda não foi completamente explorado sobre a geração de tal fenômeno constitui-se da relação entre as propriedades do material de fricção e a propensão à ocorrência de squeal noise. Este trabalho apresenta o desenvolvimento de um número adimensional obtido através de análise dimensional (teorema de Buckingham) capaz de relacionar a ocorrência de squeal noise as quatro principais propriedades dos compósitos de fricção: dureza, tamanho de partícula e concentração do abrasivo utilizado na formulação, além de sua compressibilidade. Resultados experimentais foram obtidos a partir de ensaios desenvolvidos com seis diferentes materiais de fricção nos quais a concentração ou dureza ou tamanho de partícula foi alterada de modo a oportunizar a identificação do impacto destas variáveis sobre a ocorrência de squeal noise. A ocorrência de ruídos foi verificada através da aplicação de um método de ensaio em dinamômetro inercial especialmente desenvolvido a um conjunto de amostras dos materiais de fricção moldados a pastilhas de freio e aplicados a um sistema de freio a disco convencional. Os resultados obtidos validaram o número adimensional proposto (índice de excitação 2) na medida em que foi possível estabelecer sua relação com a ocorrência de ruídos verificada experimentalmente através de uma equação logarítmica (R²=0,9). Foi estabelecida também uma relação entre o aumento do coeficiente de atrito, em função da redução da velocidade de escorregamento, e o aumento da ocorrência de squeals. Uma breve investigação a respeito da relevância da rigidez de contato sobre o comportamento vibroacústico do sistema de freio também é conduzida, tendo sido demonstrado que o aumento da magnitude desta propriedade reduz a ocorrência de ruídos do tipo squeal. / Automotive brake systems are very often susceptible to generate high frequency noise as a result of a self excited vibration. This phenomenon is generically nominated brake squeal noise and is the subject of many studies which intend to identify and describe its exciting mechanism and to propose counter measures to avoid its occurrence. One key subject yet to be explored about squeal noise generation is the relation between friction material properties and its occurrence propensity. This work presents the development of an adimentional number obtained by dimensional analysis (Buckingham theorem) capable to relate the squeal noise occurrence with four main properties from the friction composite: abrasive hardness, particle size and concentration and also its compressibility. Experimental results were obtained by testing six different friction material formulations, in which the concentration of abrasive or its hardness or its particle size was altered in order to explore the impact of these variables on the squeal noise occurrence. The noise generation was accessed by testing the friction materials molded to brake pads using a standard disc brake system in an inertial dynamometer under a specially developed test procedure. The obtained results validated the proposed adimentional number (excitation index 2) since was possible to establish a logarithmic equation (R²=0,9) relating it to the squeal noise occurrence verified on the conduced tests. It was also established a relation between the friction coefficient increase, as a function of the sliding speed reduction, with the increase on squeal noise occurrence. A brief investigation about the relevance of the contact stiffness to the vibroacustic behavior of the brake systems was developed, showing that higher values of this property can reduce the squeal noise generation.

The paper overviews the modes of vibration of the principal component parts of a brake and their contribution to system instability during noise generation. It is shown that both in-plane and out-of-plane vibration is present and that both can be related to the vibration of the pad. It is further shown that the pad and its region often provide a solution or 'fix' towards noise prevention and it is this area that forms the focus of this investigation. The collective evidence, proposals and associated theory are applied to real brake case studies when it is demonstrated that disc/pad interface 'spragging' may be the source of brake noise. Measurements of the position of the dynamic centre of pressure (CoP) support the theoretical predictions that a leading CoP induces brake noise. Design proposals are suggested that may be applied early in the design phase as a means to reduce the propensity of a brake to generate noise.

Brake squeal is an old and well-known problem in the vehicle industry and is a frequent source for customer complain. Although, brake squeal is not usually affecting the performance of the brakes, it is still important to address the problem and to predict the brakes tendency to squeal on an early stage in the design process. Brake squeal is usually defined as a sustained, high-frequency vibration of the brake components, due to the braking action. By using simulation in finite element (FE) method it should be possible to predict at what frequencies the brakes tend to emit sound. The method chosen for the analysis was the complex eigenvalues analysis (CEA) method, since it is a well-known tool to predict unstable modes in FE analysis. The results from the CEA were evaluated against measured data from an earlier study. Even though there are four main mechanism formulated in order to explain the up come of squeal, the main focus in this project was modal coupling, since it is the main mechanism in the CEA. A validation of the key components in model was performed before the analysis, in order to achieve better correlation between the FE model and reality. A parametric study was conducted with the CEA, to investigate how material properties and operating parameters effected the brakes tendency to squeal. The following parameters was included in the analysis; coefficient of friction, brake force, damping, rotational velocity, and Young’s modulus for different components. The result from the CEA did not exactly reproduce the noise frequencies captured in experimental tests. The discrepancy is believed to mainly be due to problems in the calibration process of the components in the model. The result did however show that the most effective way to reduce the brakes tendency for squeal was to lower the coefficient of friction. The effect of varying the Young’s modulus different components showed inconsistent results on the tendency to squeal. By adding damping one of the main disadvantages for the CEA, which the over-prediction of the number of unstable modes, where minimized.