Research On The Noise Of The Disc Brake Of The Car Based On Virtual Prototype

In the 21st century, the consciousness of environmental protection is strengthened day by day, the car not only meets the demands such as high-speed, heavily loaded, safe, reliable, comfortable, operated easily, but also low noise. As one important part of the car noise, the brake noise has become an important problem that is a strong common view and demanding to prompt solution by auto companies and even whole society to study.Combines an actual subject and regarded the disc brake of one type car as study object, this paper does some researches on the noise problem when it is working, and based on the theory of vibration, it establishes the relation between the brake's vibration and noise according to the relation between the amplitude and value of vibration velocity. So it proves that the parameter of structure is an important factor which influences the brake noise.The paper set up the virtual prototype of brake system in the three-dimension design software-CATIA V5 by combining two methods which are Bottom-up and Top-Down ways to building the model by using of PDG, ASD, KIN and FIT modules of CATIA to finish the model installation, the interference of static and dynamic checking, movement emulation, which make preparation to the virtual prototype design.Next, each part of the brake (Brake disc, brake pad, brake caliper, brake stand) has been led into ANSYS by Model form from CATIA V5. After choice the element, divide the net, restrain the border conditions and choose the range of calculate frequency and so on to set up the finite element model, we choose the way of Block Lanczos to modal analysis. And then compare to the test data from the manufacturer, we find out the corresponding modal. So, aimed at the modal with a big change of the structural amplitude, we put forward a concrete modification plan, then modify the structure and analyze the modal. The result of calculation indicates: compared with the original structural amplitude of each spare part, there is an obvious reduction. Especially the amplitude of brake pincers, which may be nearly neglected after revised. Therefore it is an effective way to reduce the brake noise by application of modal analysis and structure revising.Finally, Based the analysis of theory modal, a modal testing program has been designed according to the existing test equipments, which prepares for the next testing of the vibration and noise.By the research of this paper, the structure revising of the disc break is an effective way to reduce the brake noise, and provide with methods for the product improved of the corporation.