• Journal of the Korean Society of Manufacturing Process Engineers
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• v.11 no.3
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• pp.55-61
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• 2012

The structure of winch brake disk was successfully designed and developed based on sizing optimization. In this research, static analysis was performed by commercial software ANSYS v12.0. To simulate the working process of disk brake, the real properties of materials and working conditions were considered. Based on the results of the static structural analysis, the existing designs of the brake discs were optimized. Among existing designs, there are three cases that have achieved an efficient light weight around 200g. As a result, the optimized weight of each case was 3.41kg, 3.42kg, and 3.44kg, respectively. Finally, through prototyping and performance testing, the stability of the optimized brake disc was verified. Although, this free-fall winch brake disk had been developed in design and evaluation techniques, more detailed plans for developing the disk brake structure were also proposed as a further study based on this research.

• Journal of Power System Engineering
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• v.12 no.3
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• pp.44-49
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• 2008

In this research, I would like to choose sliding distance and ventilated hole number which affect to the amount of wear of disk and pad as experiment conditions of 'the amount of wear' through wear test of motorcycle brake disk. Also, I analyze the amount of wear according to the variation of coefficient of friction by using design of experiment that is being widely used in diverse areas. With the tests of least, I present the correlation of each experiment condition. Therefore, I analyzed the variation of the amount of wear of disk and pad according to test factors such as ventilated hole number, applied load, sliding speed, and sliding distance in wear test of motorcycle brake disk by applying the design of experiment. Also, I analyzed quantitatively the influence of test factors through Taguchi Robust experimental design, response surface and examined the most suitable level and estimation of the amount of wear of disk. From these, I reached the following conclusions. response surface design, mathematical model was constructed about amount of wear of disk and pad. The amount of wear that decrease according to increase of ventilated hole number, and it's increase according to Increase of applied load, sliding speed, and sliding distance.

• Tribology and Lubricants
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• v.18 no.6
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• pp.384-388
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• 2002

The adequate design of a passenger car braking system, which is directly related to the safety of a car, is very important since the safety is an essential design parameter of a car to keep men and car from the damage. The thermal behaviors of the ventilated disk has been investigated based on the air cooling effects during repeat braking operations. In this study, the thermal behavior of ventilated disk brake system was investigated by numerical method. The 3-Dimensional unsteady model was simulated by using a general purpose software package “FLUENT” to obtain the temperature distributions of disk and pad. The model includes the more realistic braking method, which repeats braking and release. The effects of aspect ratio of ventilated hole on the heat dissipation was investigated.

• Proceedings of the Korean Society for Noise and Vibration Engineering Conference
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• 2003.11a
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• pp.655-659
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• 2003

In this study, an improved topology design methodology that is combined with genetic algorithm, response surface method is provided to overcome the limitations of the ordinary topology optimization methods on the complex non-linear problem. the method is applied to a disc brake system for reducing an automobile brake noise. The low frequency that may induces the brake noise under the unstable mode is increased by obtaining the optimal topology. The result is verified by the analysis of variance and confirmed that the estimators for the approximation equations are highly reliable

• Proceedings of the KSME Conference
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• 2001.06a
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• pp.764-769
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• 2001

Brake-induced vibrations of a vehicle such as brake judder are determined by the excitation of brake torque variations and by their transfer to the driver's contact points via suspension, body and steering system. The formation of brake torque variation is mainly determined by static and dynamic disk thickness variations. The vibration transfer from the excitation by brake torque variation to the perception by the driver depends on the kinematic and dynamic behaviour of the components in the transfer path. Optimization of the judder performance can be achieved either by minimizing the excitation or by reduction of the judder sensitivity of the vehicle. In this paper, the optimization process of a front rotor is suggested to reduce brake judder considering the cooling performance of the rotor, the judder sensitivity of the vehicle and durability of the rotor.

• Proceedings of the Korean Society for Noise and Vibration Engineering Conference
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• 2005.05a
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• pp.236-240
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• 2005

This paper deals with friction-induced vibration of disc brake system under constact friction coefficient. A linear, finite element model to represent the floating caliper disc brake system is proposed. The complex eigenvalues are used to investigate the dynamic stability and in order to verify simulations which are based on the FEM model, The comparison of experimental and analytical results shows a good agreement and the analysis indicates that mode coupling due to friction force and geometric instability is responsible fur disc brake squeal. And the Front brake system reduced the squeal noise using design of experiment method(DOE). This helped to validate the FEM model and establish confidence in the simulation results. Also they may be useful during real disk brake model.

• Journal of Power System Engineering
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• v.10 no.3
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• pp.67-72
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• 2006

The effect of manufacturing parameters on wear and improve cooling of motorcycle break system was studied using a disk-on-pad type friction tester. Such parameters conditions have an effect on the wear and improve cooling factor such as applied load, sliding speed, frictional time and number of ventilated disk hole. However, it is difficult to know the mutual relation of these factor. In this study, the wear and cooling characteristics using design of experiment containing 4 elements were investigated for an optimal condition for the best motorcycle disk break system employing Taguchi robust experimental design. From this study, the result was shown that vents have an effect on convection area improving more cooling ability and reduced wear of the disk.

• Transactions of the Korean Society of Automotive Engineers
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• v.15 no.1
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• pp.125-132
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• 2007

Within the framework of brake-by-wire technology, this paper presents five types of novel models of electro-mechanical disk brake calipers with self-servo mechanism which provides self-servo effect of boosting a friction force generated between the brake pad and the rotor disk surface. The models have been developed utilizing patent map analysis results of previous invents of electro-mechanical brake calipers. The feasibility of the developed motor-driven brake caliper models have been validated through the dynamic simulation analysis. Among the developed models, the caliper mechanism with separated pressure plate was designed especially in detail and was made as a pilot. The pilot caliper has been installed on the simple test bed constructed with domestic passenger car brake components, and its function and effectiveness have been validated through several types of experimental tests.

• Composites Research
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• v.15 no.1
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• pp.41-52
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• 2002

This paper presents the thermo-elastic analysis for searching the behavior of carbon/carbon brake system during the braking period and the 3-D stress analysis to find the shape of the brake disk which is safe to the failure. The mechanical properties of the carbon/carbon brake disk were measured for both in-plane and out of plane directions. The mechanical properties were used as the input of the thermo-elastic analysis and 3-dimensional stress analysis for the brake disk. The gap between rotor clip and clip retainer is an important parameter in the loading transfer mechanism of the rotor disk. The change of gap was considered both the mechanical deformation and thermal deformation. Because the rotor clip and clip retainers were not contacted, they were excluded from the analysis model. Rotor disk was modeled by using the cyclic symmetry condition. The contact problems between rotor clip and key drum as well as between rotor disk and rotor were considered. From the results of the 3-D stress analysis, the stress concentration at the key hole of the brake disk was confirmed. The stress distributions were studied thor the variation of the rotation angle of the contact surface and the radius of curvature at the key hole part.

• Transactions of the Korean Society for Noise and Vibration Engineering
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• v.16 no.8 s.113
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• pp.830-839
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• 2006

The phenomenon of squeal noise in the disk brake system has been, and still is, a. problem for the automotive industry. Extensive research has been carried out in an attempt to understand the mechanism that causes squeal noise and In developing design procedures to reduce squeal noise to make vehicles more comfortable. In this paper, the study on the analysis of squeal noise is performed by using computer aided engineering to design the anti-squeal noise disk brake system. The first part describes the chassis dynamometer and the testing procedure, and second part explains the finite element model and the complex eigenvalue analysis. Finally, it is shown that the proposed squeal noise analysis could be useful to investigate the design parameters that affect the squeal noise characteristics.