Brake Development Process by Mercedes-Benz Cars

During the development process of new brake systems, NVH, Durability, Safety, and Comfort remain the most important factors to be considered. On one hand, numerical simulation has already been established as a fundamental tool for many successful projects in the industry. On the other hand, the key cross-correlation between different global targets and methodologies must be oriented to the best vehicle solution as a whole. In principle, brake noise and comfort are well interrelated in terms of customer satisfaction. Durability is also directly involved; however this topic is more related as a Safety topic in the project. For the brake noise problem, two main strategies are proposed: finite element method based on instability analysis and multi-body-dynamic-simulation. The instability analysis is based on complex eigenvalue solution which is the preferred methodology applied in the industry. At this point, different strategies to assess the post processing of instability frequencies have been developed together with Altair to have a better understanding of the problem. Basically, the idea is to propose additional alternatives to visualize the modal instability and to have the possibility to quantify the most important component contributions. The multi-body-dynamic-simulation is, in general, applied to problems regarding low frequency phenomena, for instance moan and groan noise problems. The modelling process is based on flexible body combined with kinematics, which include axle components as well. Additional tools, such as optimization strategy, i.e., topology and shape optimizations, are well applied for durability and comfort problems. To summarize, the main focus in this work is to give a general view about the best compromise solution and the current tools applied during the development process of a brake system.

The Author

Dr. Ronaldo F. Nunes, Arnaud Heussaff
Daimler AG, Mercedes-Benz Car - Sindelfingen