Numerical methods for brake squeal analysis are widely accepted in industry. The use of complex eigenvalue analysis is a successful approach to predict the appearance of squeal noise. Using simulation in an early design stage reduces time to market, saves costs, and improves the physical behavior and robustness of the brake system.
State of the art of brake simulation comprises sampling for many parameter sets in a wide range of interesting values. Based on high performance, stability maps can be created in short time containing many results, which gives a deep insight into the brake behavior under varying parameters.
An additional benefit of sampling is the possibility to detect parts with high potential for improving the NHV comfort. In the sequel, mathematical optimization methods like topology optimization or shape optimization are used for systematic improvements. Beside optimization of parts, the optimization of the complete brake system behavior during complex eigenvalue analysis is the main target of the process to reduce squeal noise. Finally, a stability map is created again to verify the improvements of the brake system.
The paper shows the extended simulation process including optimization by using the example of a PORSCHE production brake system. The integrated calculations and optimizations are performed by the Finite Element Analysis Software PERMAS.