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Brake squeal noise is a top warranty concernsmplaints for virtually all automotive companies. How to identify squeal frequencies and mode shapes is typically very challenging. The identification of potential squeal problems still rely heavily on experimental methods using inertia and chassis dynamometers or on-road tests, but these require hardware to run. Good numerical methods have advantages of evaluating up-front designs before the cutting tools ever hit any metal. But for brake squeal, there are still many challenges to overcome to correctly model a complete brake system due to the nature of the complexity of the frictional excitation. In this paper, a disc brake system model was established to simulate brake squeal using nonlinear transient analysis methods provided through LS-DYNA. The model includes rotor, pads, linings, caliper and pistons. From the example analyzed, the squeal frequency is identified using frequency domain analysis of the numerical time-domain output.

This paper reviews the state of the art of CAE simulation and analysis methods on disc brake squeal. It covers complex modes analysis, transient analysis, parametrical analysis, and operational simulation. The advantages and limitations of each analysis method are discussed. This review can help analysts to choose right methods and decide new lines of method development. For completeness, analytic methods dealing with continuum models are also briefly covered. This review was made from those papers that the authors are familiar with. It is not meant to be all-inclusive even though the best possible effort has been attempted.