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The drum brake pulsation is an issue that may cause a major customer complaint. One of the root causes of the drum pulsation is the deformation of the drum to an out of roundness (OOR) shape during the wheel-drum-axle assembly process under the presence of the uneven wheel flatness. This paper summarizes the newly developed OOR simulation method using ABAQUS and the counter-measures to reduce the OOR, and subsequently pulsation, by identifying the drum design parameter effects on OOR.

Brake insulators often offer optimal solutions to squeal noise. In the process of engineering solutions to reduce the brake noise, a system-level finite element complex eigenvalue analysis is often used and has gained popularity in recent years. Models of insulators have also been proposed for system-level evaluation, however many challenges remain in efficiently implementing an insulator model, owing to complexities of the insulator component model. The complexities arise from the visco-elastic behavior (primarily the frequency and temperature dependence), and the thin polymer/steel multi-layer nature of the construction - typical in an insulator. As a first part of a joint investigation, this paper explores the nature of frequency and temperature dependence in insulator models and reduces the cumbersome multi-layer model into a simpler form that can be more easily implemented in a typical brake system stability analysis.