降低制动摩擦振动的制动器结构拓扑优化设计

Topology Optimization Design of Brake Structure to Reduce Friction-induced Vibration and Noise

本文建立起某车型盘式制动系统三维有限元模型,分析了该制动系统的摩擦振动噪声特性,并基于ABAQUS/Optimization模块对该制动系统进行结构拓扑优化设计,在满足轻量化的目标要求下改善摩擦振动噪声问题。结果表明:制动系统在摩擦力作用下可能出现四种振动模态,且产生频率为3632.4 Hz的振动噪声的倾向和强度最大。产生该频率摩擦振动噪声的原因是由于制动钳的第4阶模态频率与制动盘的第11阶模态频率非常接近,在摩擦力作用下容易产生共振。通过对制动钳进行结构拓扑优化设计,移除制动钳两侧区域的材料,使其在满足重量最小的目标前提下将第4阶模态频率降低到2804 Hz,从而避免与制动盘发生共振,且制动钳的重量减轻了17.1%。进一步采用复特征值分析对结构优化后的制动系统进行摩擦振动噪声特性预测,结果表明制动系统仅有两组相邻模态出现模态耦合现象,且原始制动系统出现的3632.4 Hz的振动噪声频率已经消失,制动系统摩擦振动噪声问题得到显著改善。

In this work,a three-dimensional finite element model of a vehicle disc brake system is established,and the friction-induced vibration and noise characteristics of the brake system are analyzed.Then ABAQUS/Optimization module is used to perform structural topology optimization design for the caliper of brake system,to meet the requirements of lightweight goals and improve the friction-induced vibration and noise problem.Results show that there are four vibration modes generated from the brake system,and the tendency and intensity of vibration noise are the highest at the frequency of 3632.4 Hz.The reason for the occurrence of this frequency is that the 4th mode of brake caliper is close to the 11th mode frequency of brake disc,and the modal coupling phenomenon is easy to occur during friction process.Through the topological optimization design of the brake caliper body and the removal of materials on both sides of the brake caliper,the 4th mode of the brake caliper is reduced to 2804 Hz to avoid resonance with the brake disc under the premise of meeting the goal of minimum weight,and the weight of the brake caliper is reduced by 17.1%.The complex eigenvalue analysis is further used to predict the vibration and noise of the braking system after the structural optimization.The results show that only two adjacent modes of the braking system generate modal coupling phenomenon,and the vibration and noise frequency of 3632.4 Hz is disappeared,indicating that the vibration and noise problem of the brake system has been significantly improved.