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The Analysis of Brake Squeal Noise Related to the Friction Properties of Brake Friction Materials

Hyundai Motor Company-Sang-mok Lee, Jung Hoon Woo, Dong Won Kim
Hyundai Motor Company & KIA Motors Corporation-Younggu Cho
Published 2019-09-15 by SAE International in United States
The friction properties related to squeal noise was analyzed with the development histories and simplified computational method. Firstly, the development histories were investigated especially focusing on the case which the friction materials were modified to improve squeal noise occurrence. Based on the histories, the friction properties of selected friction materials were newly measured using dynamometer. The average friction coefficient levels, torque oscillations, the increment of friction coefficient during full-stop, and etc. were compared with the squeal noise occurrence, and the results showed that increase of friction properties cause production of squeal noise. The result suggested that the size of friction energy was important factors related to triggering the squeal noise. Also, the contact conditions between rotor disc and friction materials were significant factors deciding the noise occurrence. We performed simplified computational analysis using MATLAB program to prove the effect of friction energy on the noise occurrence. The friction surfaces were roughly designed and the distribution of contact plateaus was controlled to simulate different contact conditions. The different contact conditions were designed and performed sliding at…
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A Study on the Optimum Reduction of Required Brake Fluid Level for Improvement of the High Speed Continuous Brake Distance

Hyundai Motor Company-Junggyu Kim, Kwang Yun Kim, Eue-sub So
Published 2019-09-15 by SAE International in United States
The high speed continuous braking distance assessment is the worst condition for thermal fades. This study was conducted to investigate the relationship between fade characteristic and friction materials & brake fluid amount for improving braking distance. So, we used the dynamometer to measure the friction coefficient, braking distance and required brake fluid amount. Through the measurements, the research was carried out as follows. First of all, we studied the influence of friction coefficient about different shapes (chamfer shape, area of the friction material, number of slots) on the same friction material. Secondly, we knew the effects of braking distance by the shape of the friction material. Through these two studies, the shape of the friction material favorable to the fade characteristics was derived. Finally, we measured the amount of required brake fluid in caliper after 10 consecutive braking cycles through Dynamometer. And then, we measured the amount of compression deformation and uneven wear of the friction material. It was found that the above two factors cause the increase the amount of required brake fluid. Through…
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A Study of the Disc Scoring Generation Principle and Reduction(III)

Hyundai Motor Company-ByeongUk Jeong, Hyoung Tae Ryu
Myunghwa Ind Co., Ltd.-Chang Jin Kim
Published 2019-09-15 by SAE International in United States
In the latest works [12], we presented the guideline for reducing Metal pick up(MPU, the main component of disc scoring) by controlling the location of the roughness of disc, the brake pad friction coefficients and the disc slot's size. In this study, the previously studied iron transfer theory to 'Cu free' brake pad and the disc surface roughness controlling methods which are based on the mass production manufacturing process are applied. It is possible to suggest the ways to improve the scoring-free disc without reducing friction coefficient between the disc and pad, and any demerit such as increased wear and airplane noise like conventional slot discs [11].
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Extensive Correlation Study of Acoustic Trim Packages in Trimmed Body Modeling of an Automotive Vehicle

Hyundai Motor Company-Ki-Sang Chae
Free Field Technologies-Markus Brandstetter, Jonathan Jacqmot
Published 2019-06-05 by SAE International in United States
In the automotive sector, the structure borne noise generated by the engine and road-tire interactions is a major source of noise inside the passenger cavity. In order to increase the global acoustic comfort, predictive simulation models must be available in the design phase. The acoustic trims have a major impact on the noise level inside the car cavity. Although several publications for this kind of simulations can be found, an extensive correlation study with measurement is needed, in order to validate the modeling approaches. In this article, a detailed correlation study for a complete car is performed. The acoustic trim package of the measured car includes all acoustic trims, such as carpet, headliner, seats and firewall covers. The simulation methodology relies on the influence of the acoustic trim package on the car structure and acoustic cavities. The challenge lies in the definition of an efficient and accurate framework for acoustic trimmed bodies. Two different approaches to achieve this objective are reviewed. In the first approach, the acoustic trim package is modeled as a set of…
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A Study on NVH Performance Improvement of TPE Air Intake Hose Based on Optimization of Design and Material

Hyundai Motor Company-Hyunsoo Jung, Jong Min Park
DuPont China Holding Co., Ltd.-Yu Gu
Published 2019-06-05 by SAE International in United States
Environmental and fuel economy regulations (Eu 6d and WLTP RDE) on automobiles have been tightened recently. To counter this regulation, the global automobile industry is focusing on weight reduction, fuel efficient turbo charger, cooled EGR, thermal management, low friction and so on. However, the high-speed turbocharger makes turbulence, and resulting in airflow noise. This noise is transmitted indoor through the air intake system, which adversely affects the vehicle's competitiveness. Therefore, for turbo engine, it is essential to reduce the noise of the air intake system. The air intake system consists of air cleaner, air filter, air intake hose and air duct. The air flow noise of turbo-engine is mainly the emission noise emitted from the walls of air intake system. And the transfer path of turbo noise is in order of air intake hose, air cleaner and air duct. Therefore, it is effective to reduce the noise of the air intake hose located at the beginning of noise transfer path. In the past, rubber hoses with vibration and acoustic insulation were mainly used to reduce…
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Improvement of Steering Performance Using Steering Rack Force Control

Hyundai Motor Company-Chanjung Kim, Dayul Son
Hyundai Mobis-Byoungyun Lee
Published 2019-04-02 by SAE International in United States
Drivers continually require steering performance improvement, particularly in the area of feedback from the road. In this study, we develop a new electrically-assisted steering logic by 1) analyzing existing steering systems to determine key factors, 2) modeling an ideal steering system from which to obtain a desirable driver torque, 3) developing a rack force observer to faithfully represent road information and 4) building a feedback compensator to track the tuned torque. In general, the estimator uses the driver torque, assist torque and other steering system signals. However, the friction of the steering system is difficult to estimate accurately. At high speed, where steering feeling is very important, greater friction results in increased error. In order to solve this problem, we design two estimators generated from a vehicle model and a steering system model. The observer that uses two estimators can reflect various operating conditions by using the strengths of each method. Therefore, it reflects the driving situation more precisely. We evaluated real vehicle performance under various operating conditions to compare the actual rack force and…
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A Development of the Holographic Lighting

Hyundai Motor Company-Byoungsuk Ahn, Jinho Na, Kihong Lee
SL Corporation-Jinho Jo
Published 2019-04-02 by SAE International in United States
A signal lamp performs a function to inform the position and behavior of the vehicle. And it represents a specific design identity of the vehicle or brand identity. Recently it implements the unique three-dimensional effect while using a LED. However, a number of LEDs and complex form of the lens shape have to be applied, so results in the size, weight, cost increase. In this study, the hologram technology that is an exemplary technique for implementing the described three-dimensional image is applied. With a hologram, it is possible to reproduce a complex shape three-dimensional image by using a hologram film. Therefore the number of parts can be reduced. And it is possible to copy the film has a mass production benefits.
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Effects of Bore-to-Stroke Ratio on the Efficiency and Knock Characteristics in a Single-Cylinder GDI Engine

Hyundai Motor Company-Byeongseok Lee, Dongwon Jung, Soo Hyung Woo
Seoul National University-Seokwon Cho, Sechul Oh, Chiheon Song, Woojae Shin, Sejin Song, Han Ho Song, Kyoungdoug Min
Published 2019-04-02 by SAE International in United States
As a result of stringent global regulations on fuel economy and CO2 emissions, the development of high-efficiency SI engines is more urgent now than ever before. Along with advanced techniques in friction reduction, many researchers endeavor to decrease the B/S (bore-to-stroke) ratio from 1.0 (square) to a certain value, which is expected to reduce the heat loss and enhance the burning rate of SI engines. In this study, the effects of B/S ratios were investigated in aspects of efficiency and knock characteristics using a single-cylinder LIVC (late intake valve closing) GDI (gasoline direct injection) engine. Three B/S ratios (0.68, 0.83 and 1.00) were tested under the same mechanical compression ratio of 12:1 and the same displacement volume of 0.5 L. The head tumble ratio was maintained at the same level to solely investigate the effects of geometrical changes caused by variations in the B/S ratio. In addition, because the engine was equipped with a dual CVVT (continuous variable valve timing) system, the valve timings were optimized to fully exploit the potential of each geometry. As…
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The Development of a NOx Reduction System during the Fuel Cut Period for Gasoline Vehicles

Hyundai Motor Company-Muyoung Choi, Eunsang Lee, Sangjin Ma, Sangmin Lee, Jungmin Seo, Seungbeom Yoo
Heesung Catalysts-Jinwoo Song, Jun Lee
Published 2019-04-02 by SAE International in United States
Generally, vehicles do not need power during deceleration. Therefore, the fuel efficiency can be improved by stopping the fuel injection in this period. However, when the fuel cut is activated, NOx is emitted immediately after fuel cut. During the fuel cut period, a large amount of fresh air flows into the catalytic converter installed on a vehicle since there is no combustion. Thus, the catalytic materials are converted into an oxidizing atmosphere. As a result, NOx purification performance of the catalyst deteriorates, and eventually NOx is emitted when combustion restarts. The quantity of NOx in this period is relatively small. However, in case of increasing fuel cuts, emission problem could arise. Therefore, in order to meet the stringent regulation such as LEV III-SULEV20 or 30, the number of fuel cuts need to be limited. The problem is that this strategy leads to a disadvantage of fuel efficiency. In order to solve this problem, in this study, the principle and process of NOx during the fuel cut period was analyzed in detail and then a new…
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A Study of Design Methodology to Develop Improved Door System of a Vehicle

Hyundai Motor Company-Je-Won Choi
Published 2019-04-02 by SAE International in United States
In the past few years, technological innovations in the automobile industry took vehicle performance to the next level. One such innovation is frame integrated panel door. This type of door helps automobile companies to have the advantages of both conventional panel and frame type doors. Though it has a good number of advantages, there are some drawbacks too. It requires improvements in its quality, NVH performance, weight and etc. Quality of a door is low due to the limitations in structural design and manufacturing technologies. And it is difficult to have a robust structure which leads to degradation of key performing factors such as NVH. For a lightweight vehicle, it is important to design an optimized structure for saving weight, without compromising its performance. In order to overcome these drawbacks a new optimized design structure is required for door system. This Research paper is about a systematic design methodology for Development of a new optimized door structural design by a comprehensive engineering design analysis of existing design constrains and drawbacks. The design methodology is described…
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