This paper considers a study of the thermo-elastic behaviour of a disc brake during heavy braking. The work is concerned with working towards developing design advice that provides uniform heating of the disc, and equally important, even dissipation of heat from the disc blade. The material presented emanates from a combination of modeling, on-vehicle testing but mainly laboratory observations and subsequent investigations. The experimental work makes use of a purpose built high speed brake dynamometer which incorporates the full vehicle suspension for controlled simulation of the brake and vehicle operating conditions. Advanced instrumentation allows dynamic measurement of brake pressure fluctuations, disc surface temperature and discrete vibration measurements. Disc run-out measurements using non-contacting displacement transducers show the disc taking up varying orders of deformation ranging from first to third order during high speed testing. This surface interrogation during braking identifies disc deformation including disc warping, 'ripple' and the effects of 'hot spotting'. The mechanical measurements are complemented by thermal imaging of the brake, these images showing the vane and vent patterns on the surface of the disc. The results also include static surface scanning, or geometry analysis, of the disc which is carried out at appropriate stages during testing. The work includes stress relieving of finished discs and subsequent dynamometer testing. This identifies that in-service stress relieving, due to high heat input during braking, is a strong possibility for the cause of disc 'warping'. It is also seen that an elastic wave is established during a braking event, the wave disappearing on release of the brake.

Yes / Braking-induced forced vibration, known as brake judder in road vehicles, causes dissatisfaction to drivers and passengers and also damage and possible early failure in components and systems. In this paper, the transmission of judder vibration from the point of generation (the brake friction pair) through the vehicle structure to the driver is investigated for the particular case of a heavy commercial vehicle. The investigation uses a computer simulation multi-body dynamic model based on the automatic dynamic analysis of mechanical systems software to identify any characteristics of the vehicle suspension design that might influence the vibration transmission from the wheel to the driver. The model uses a simplified rigid chassis and cab to lump the chassis parameters, so that the investigation can focus on the front axle/suspension design, which is a beam axle leaf spring arrangement, and the rear axle/suspension assembly, which is a tandem axle bogie design. Results from the modelling indicate that brake judder vibration is transmitted to the chassis of the vehicle through a leaf spring `wind-up¿ mode and a `walking¿ mode associated with the rear tandem axle. Of particular interest is the longitudinal vibration transmitted through the chassis, since this creates a direct vibration transmission path to the cab and driver. The simulation results were compared with the previously published experimental work on the same design of commercial vehicle, and agreement between the predicted and the measured vibration characteristics and frequencies was found. It is concluded that the rear suspension design parameters could affect the transmission of brake judder vibration to the cab and driver and that a tandem rear axle offers some design opportunity to control the transmission of brake judder vibrations from the wheel to the cab and driver. Given that brake judder has so far defied all attempts to eliminate completely from vehicle brake systems, this is potentially an important opportunity.

Hot spotting of automotive disc brakes is an undesired thermal localisation phenomenon, which is a challenge for numerical modelling in terms of both accuracy and efficiency especially for complex disc geometry. In this research, the aim was to develop a computationally efficient finite element (FE) approach for 2-piece pin-mounted ventilated disc hot spot prediction with acceptable accuracy enabling parametric studies to contribute to the knowledge of the complex mechanisms. A time reduction strategy for the simulations was established by incorporating an axisymmetric brake pad assumption with material scaling factor and the friction characteristics were defined by a user-subroutine. The computing accuracy and efficiency of this method were then verified by comparing with traditional FE models. 2D in-plane, 2D out-of-plane, and 3D models were performed to investigate the effects of ventilated disc hot spotting, radial hot spot/band migration, and hot spotting of realistic complex disc geometry respectively. Both 2D and 3D results were validated using experimental results based on a laboratory dynamometer and showed good correlation. The results suggested that adequate modelling of friction pair contact pressure distribution and the subsequent non-uniform heat generation is essential for hot spot simulation; speed was identified as the determinant for the number of hot spots, whereas hot spot temperature was determined by energy level. Furthermore, recommendations for vent design, pins, disc run-out, cooling, material selection, wear rate, pad length and loading distribution were given. Finally, hot spotting and hot band migration cause-effect chains were established based on the results and discussion.

Hot spotting of automotive disc brakes is an undesired thermal localisation phenomenon, which is a challenge for numerical modelling in terms of both accuracy and efficiency especially for complex disc geometry. In this research, the aim was to develop a computationally efficient finite element (FE) approach for 2-piece pin-mounted ventilated disc hot spot prediction with acceptable accuracy enabling parametric studies to contribute to the knowledge of the complex mechanisms. A time reduction strategy for the simulations was established by incorporating an axisymmetric brake pad assumption with material scaling factor and the friction characteristics were defined by a user-subroutine. The computing accuracy and efficiency of this method were then verified by comparing with traditional FE models. 2D in-plane, 2D out-of-plane, and 3D models were performed to investigate the effects of ventilated disc hot spotting, radial hot spot/band migration, and hot spotting of realistic complex disc geometry respectively. Both 2D and 3D results were validated using experimental results based on a laboratory dynamometer and showed good correlation. The results suggested that adequate modelling of friction pair contact pressure distribution and the subsequent non-uniform heat generation is essential for hot spot simulation; speed was identified as the determinant for the number of hot spots, whereas hot spot temperature was determined by energy level. Furthermore, recommendations for vent design, pins, disc run-out, cooling, material selection, wear rate, pad length and loading distribution were given. Finally, hot spotting and hot band migration cause-effect chains were established based on the results and discussion. / Appendix 1 and Appendix 2 are unavailable online due to copyright restrictions.

Over the past decade vehicle judder caused by Disc Thickness Variation (DTV) has become of major concern to automobile manufacturers worldwide. Judder is usually perceived by the driver as minor to severe vibrations transferred through the chassis during braking [1-9]. In this research, DTV is investigated via the use of a Smart Brake Pad (SBP). The SBP is a tool that will enable engineers to better understand the processes which occur in the harsh and confined environment that exists between the brake pad and disc whilst braking. It is also a tool that will enable engineers to better understand the causes of DTV and stick-slip the initiators of low and high frequency vibration in motor vehicle brakes. Furthermore, the technology can equally be used to solve many other still remaining mysteries in automotive, aerospace, rail or anywhere where two surfaces may come in contact. The SBP consists of sensors embedded into an automotive brake pad enabling it to measure pressure between the brake pad and disc whilst braking. The two sensor technologies investigated were Thick Film (TF) and Fibre Optic (FO) technologies. Each type was tested individually using a Material Testing System (MTS) at room and elevated temperatures. The chosen SBP was then successfully tested in simulated driving conditions. A preliminary mathematical model was developed and tested for the TF sensor and a novel Finite Element Analysis (FEA) model for the FO sensor. A new method called the Total Expected Error (TEE) method was also developed to simplify the sensor specification process to ensure consistent comparisons are made between sensors. Most importantly, our achievement will lead to improved comfort levels for the motorist.

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