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Ⅰ. 서론 14

1.1. 연구 배경 14

1.2. Disc Brake 면압 연구의 필요성 15

1.3. 선행 연구 동향 16

1.3.1. 1차원 Geometry의 COP 해석 17

1.3.2. 정적 Pad 면압 분포 연구 18

1.3.3. 동적 Pad 면압 분포 계측 연구 20

1.4. 본 연구의 방향 21

Ⅱ. 해석 대상 및 모델링 23

2.1. Air Disc Brake 동적 거동 해석 23

2.1.1. Pad 무게 중심 (COG, Centre of Gravity) 24

2.1.2. 등가 반경(Effective Radius) 25

2.1.3. Pad의 동적 거동 26

2.1.4. 동적 거동에 의한 Pad 면압 중심점 해석 28

2.2. Disc Brake 동적 거동 검증 방법론 37

2.2.1. Pad 물성 시험 37

2.2.2. 직교 이방재 (Orthotropic Material) 39

2.2.3. 횡 방향 등방재 (Transversely Isotropic Material) 41

Ⅲ. 유한요소 해석 및 실험적 검증 45

3.1. FE Analysis 45

3.1.1. 유한 요소 모델 45

3.1.2. 해석 조건 51

3.1.3. 해석 결과 58

3.2. Strain Test for Pad Surface Pressure 64

3.2.1. 정·동적 Pad 면압측정 방법론 64

3.2.2. 시험 장치의 구성 71

3.2.3. 면압 측정 결과 77

Ⅳ. Results and Discussion 80

4.1. COP 이론 산출 및 FE 해석결과 비교 80

4.2. FE Analysis and Strain Test 결과 비교 82

4.2.1. Inner Pad 결과 비교 82

4.2.2. Outer Pad 결과 비교 84

4.2.3. FE Analysis와 Test Results 오차율 분석 86

4.2.4. FE Analysis와 Test Results 상관 분석 88

4.2.5. FE Analysis와 마모 시험결과 비교 94

Ⅴ. 결론 95

Ⅶ. 참고문헌 97

Nomenclature 101

Abstract 102

표목차

Table 1. Geometry of Brake Pad 34

Table 2. Lab Test results of Air Disc Brake 34

Table 3. Analysis results of Pad Geometry in ADB 36

Table 4. Material property results of Brake Pad by SAE J2725 38

Table 5. ADB Function description for each part 46

Table 6. Material Property of ADB 47

Table 7. Meshing Results of ADB Modeling 48

Table 8. Contact Condition of each Components 52

Table 9. Boundary Condition at Static state 54

Table 10. Boundary Condition of Dynamic State 56

Table 11. Test Identification 56

Table 12. Load Condition 57

Table 13. Surface Normal stress of Inner Pad 58

Table 14. Surface Normal Stress Distributions of Inner Pad 59

Table 15. Surface Normal stress of Outer Pad 61

Table 16. Surface Normal Stress Distributions of Outer Pad 62

Table 17. Specification of Strain gage 67

Table 18. Test Plan (Test Input and Output) 68

Table 19. Test Bed using LabView 72

Table 20. Surface Normal stress of Inner Pad 77

Table 21. Surface Normal stress of Outer Pad 78

Table 22. COP of Theoretical Results and FE Analysis 81

그림목차

Figure 1. Conceptual Model of brake squeal noise. by Ref. [24] 15

Figure 2. FE results showing the distribution of the surface temperatures (C) and the hot-spot development at the outboard disc surface by Ref. [20] 16

Figure 3. Free body diagram of brake pad assuming coplanar frictional forces and differing abutment by Ref. [29] 18

Figure 4. Load Distribution in Pad by Ref. [33] 19

Figure 5. Dynamic contact pressure distribution of test/ improved CAE model by Ref. [7] 19

Figure 6. Pressure sensitive film and Pad assembly with film laminate sandwiched within pad Ref. [12] 20

Figure 7. Strain measured by the FBG sensors and the PSP under static loading by Ref. [10] 21

Figure 8. Contact pressure distributions of smooth and flat pads by Ref. [8] 21

Figure 9. Braking Torque Mechanism of Air Disc Brake 23

Figure 10. Geometry of Brake Pad 24

Figure 11. Non-uniform Pad Pressure by Ref. [1] 27

Figure 12. Dynamic Behavior in Brake Pad 28

Figure 13. 1-Dimensional FBD (Free Body Diagram) of ADB Pad 29

Figure 14. 2-Dimensional FBD (Free Body Diagram) of ADB Pad 30

Figure 15. COP position change at each Clamping Force in Brake Pad 35

Figure 16. Braking Torque Comparison (COP vs Test Results) 37

Figure 17. Ultrasonic velocity measurements of Pad 38

Figure 18. Elastic constants of a transversely isotropic material 42

Figure 19. FE Model of ADB (Air Disc Brake) 46

Figure 20. Convergence of FE analysis results for each mesh condition 50

Figure 21. Contact Condition of each Components 53

Figure 22. Boundary Condition of Static State 54

Figure 23. Boundary Condition of Dynamic State 55

Figure 24. Test Point of Pad Surface Pressure 57

Figure 25. Static Surface Normal Stress of Inner Pad 58

Figure 26. Dynamic Surface Normal Stress of Inner Pad 59

Figure 27. Static Surface Normal Stress of Outer Pad 61

Figure 28. Dynamic Surface Normal Stress of Outer Pad 62

Figure 29. Air Disc Brake Mechanism 64

Figure 30. Specification of Air Disc Brake 65

Figure 31. Test Points of Pad Surface Pressure 66

Figure 32. Brake Pad with Strain gage attached at 8 points 66

Figure 33. State Diagram with Rosette Strain gauge Attachment 69

Figure 34. Test Bed for Brake Surface Pressure 71

Figure 35. Measurement and Analysis Program based on LabVIEW 73

Figure 36. Measurement Part about Strain gauge 74

Figure 37. Signal Processing by LPF 75

Figure 38. Calculation Part of Strain-Stress relation Matrix 75

Figure 39. Display Part of Strain Test for monitoring 76

Figure 40. Static Surface Normal Stress of Inner Pad 77

Figure 41. Dynamic Surface Normal Stress of Inner Pad 78

Figure 42. Static Surface Normal Stress of Outer Pad 79

Figure 43. Dynamic Surface Normal Stress of Outer Pad 79

Figure 44. COP of Theoretical Results and FE Analysis 81

Figure 45. Comparison of FE analysis and Test results (Static) 83

Figure 46. Comparison of FE analysis and Test results (Dynamic) 84

Figure 47. Comparison of FE analysis and Test results (Static) 85

Figure 48. Comparison of FE analysis and Test results (Dynamic) 85

Figure 49. Error Rate of Inner Pad 86

Figure 50. Error Rate of Outer Pad 87

Figure 51. Deformation of ADB 87

Figure 52. Static Correlation Analysis of Inner Pad 89

Figure 53. Dynamic Correlation Analysis of Inner Pad 91

Figure 54. Static Correlation Analysis of Outer Pad 92

Figure 55. Dynamic Correlation Analysis of Outer Pad 93

Figure 56. Comparison of Dynamo wear test and FE analysis results 94

초록보기

 The physical function of the Disc Brake of vehicle is to convert the rotational kinetic energy of the Disc Rotor into thermal energy due to friction. The key function of this device can be said to be stable friction behavior in contact area where friction occurs. Stable friction behavior can be achieved by a constant friction coefficient and uniform surface pressure distribution in the contact area of the Pad and Disc Rotor, which can secure excellent braking power, suppress braking heat, and ensure good NVH quality.

To analyze and explain this phenomenon, a number of papers and academic studies have been conducted on the distribution of brake surface pressure. Accordingly, this paper established a further improved two-dimensional center of pressure (COP) theory and FE analysis model, and presented a new test method to verify the surface pressure distribution of Pad in a static contrast dynamic braking state.

As a result, 1) COP two-dimensional theoretical formula was derived and correlation with FE analysis results was secured. 2) A test method was proposed that can measure the distribution of surface pressure in a dynamic state in which Disc Rotor friction-rotates with Pad, and the reliability of the results was confirmed. 3) An FE analysis model was developed to confirm the distribution of Pad surface pressure in a dynamic state, and its reliability was confirmed and verified with the results of the dynamic Strain test. 4) The elastic characteristics of the friction material, a representative anisotropic material, were derived through ultrasonic dynamic characteristic tests, and its physical characteristics were described to become the accurate basis of the analysis and test model.

The core of the Foundation Brake design is to optimize the Brake structure so that the surface pressure distribution is constant. In order to achieve these high-quality design goals, Brake Geometry's decision considering the COP presented in this study is an important factor.

Furthermore, a methodology that can analyze the surface pressure distribution in the Pad Surface and supplement the surface pressure to be distributed evenly was developed through this paper. In addition, a new idea was derived to confirm the distribution of face pressure in dynamic states by overcoming the limitations that previously remained in static surface pressure measurement, and its reliability was verified through theoretical formulas, FE Analysis, and newly designed Strain Tests.

Based on the reliable Disc Brake analysis model presented, it is expected that it will be able to develop into a more accurate analysis model of heat generation, wear, and NVH.

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