Brake squeal signatures (2 kHz to 18 kHz) have tonal content highly dependent on the specific brake system structural architecture. The challenge in minimizing squeal involves correctly identifying the conditions (temperature, apply pressure, rotor speed as some basic parameters) of occurrence, defining the underlying structural dynamics of the system and applying appropriate suppression solutions. The quantitative metric of improvement is the cumulative event percentage of occurrence.
Design variables of the brake system and performance attribute targets extend the challenge beyond the level of just reducing noise. Consideration of material costs, manufacturing/assembly factors, durability, thermal management as well as other factors narrow the solution space significantly. Compressed late stage development is not uncommon in reaching acceptable levels of performance and is a primary reason for following a well defined process flow with provision for alternative solutions.
This paper describes a 5 phase engineering process with respect to development of application specific optimal brake insulator solution (s). Beginning with the baseline squeal signature analysis of phase I, the system structural dynamic characteristics and potential root cause squeal instability factors are identified within phase II. Phase III and IV are comprised of iterative insulator component level development and system level evaluation leading to phase V to determine an optimal “value” based selection and validation of insulator alternatives.