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This paper reports the results of a back-to-back comparison of the squeal and judder propensity of simple cast iron and siliconised carbon disk brake systems. A finite element simulation approach is used to predict the squeal propensity of the two systems based on the results of a complex eigenvalue analysis. These results which are validated by dynamometer noise tests carried out according to the SAE J2521 [1] standard procedure show that the siliconised carbon rotor is much less prone to squeal over the range of conditions considered. The combined experimental and numerical simulation approach is also applied to the problem of hot judder for the two rotors. The critical rotational speeds for hot spots to form are predicted to be an order of magnitude higher for the siliconised carbon rotor system. These results demonstrate the potential of the new carbon composite rotor material to reduce the occurrence of noise and vibration problems in automotive brakes.

A non-linear contact analysis of a leading-trailing shoe drum brake, using the finite element method, is presented. The FE model accurately captures both the static and pseudo-dynamic behaviour at the friction interface. Flexible-to-flexible contact surfaces with elastic friction capabilities are used to determine the pressure distribution. Static contact conditions are established by initially pressing the shoes against the drum. This first load step is followed by a gradual increase of applied rotation to the drum in order to define the maximum reacted braking torque and pseudo-dynamic pressure distribution at the transition point between sticking and sliding motion. The method clearly illustrates the changes in contact force that take place as a function of the applied pressure, coefficient of friction and initial gap between lining and rotor. These changes in contact area are shown to influence the overall stability and therefore squeal propensity of the brake assembly.