Grooved Brake Disk Structure for Squeal Noise Suppression
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Solution Overview
Problem
Braking systems in vehicles generate unpleasant squeal noise due to resonance between brake disks and pads, which can lead to wear and changes in vibration features over time, despite efforts to prevent noise during development.
Innovation Solution
A brake disk design featuring internal and external grooves with specific curvatures and symmetrical/asymmetrical shapes, combined with viscoelastic layers, to reduce resonance and noise by controlling wave reflection and cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If grooves are formed on the brake disk to restrain reflected waves, then squeal noise is reduced, but manufacturing complexity increases
Solution Approach 1:
The brake disk surface is segmented into multiple grooves (first internal grooves on the first surface, second internal grooves on the second surface, and external grooves on the circumferential portion) to break up and restrain reflected waves, thereby reducing squeal noise while distributing the complexity across multiple simple features rather than one complex feature
Solution Approach 2:
The grooves are designed with curved profiles following specific mathematical functions (power functions with predetermined exponents) rather than straight lines, creating optimal wave reflection patterns that reduce squeal noise while the curvature provides aerodynamic and structural benefits
2Object-affected harmful factors
If the groove curve follows a power function for wave restraint, then squeal noise is reduced, but manufacturing precision requirements increase
Solution Approach 1:
The groove curves are defined by power functions with predetermined exponents (e.g., y = ax^b where b is a specific value), transforming a complex geometric design problem into a parameter optimization problem. This allows standard manufacturing processes to achieve the required precision by controlling key parameters rather than complex shapes
Solution Approach 2:
The power function geometry allows the groove formation process to self-align and self-correct during manufacturing, where the mathematical relationship inherent in power functions provides natural tolerance compensation, reducing the actual precision requirements compared to arbitrary curved profiles
3Object-affected harmful factors
If internal grooves are formed on brake surfaces, then squeal noise is reduced, but braking friction is affected
Solution Approach 1:
The grooves are positioned in specific locations on the brake disk surfaces and circumferential portions, with varying depths and patterns tailored to local wave reflection needs. This localized approach restrains reflected waves in critical areas while leaving other areas intact to maintain optimal braking friction
Solution Approach 2:
Symmetrical groove patterns are copied from one brake surface to the other (first internal grooves on first surface, second internal grooves on second surface), ensuring balanced noise reduction while maintaining symmetrical braking characteristics and friction distribution across both surfaces
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The grooved brake disk effectively reduces squeal noise and wave reflection, while also enhancing cooling, thus minimizing wear and maintaining system stability.
Implementation Method 1
adding a damping member for reducing amplitudes to the brake disk
Implementation Method 2
a resonance occurs in the braking system due to the exciting energy between the brake disk and the pad
Implementation Method 3
forming grooves on the disk to restrain reflected waves generated during braking
Implementation Method 4
when the resonance exceeds a damping limit of the system, noise may be generated
Implementation Method 5
a second function for cooling the brake disk
Data Source
AI summary
A brake disk includes a first surface including a first brake surface-contacting with a brake pad, a second surface including a second brake surface, a circumferential portion connecting the first surface and the second surface, and at least one of at least one first internal groove formed on the first surface, at least one second internal groove formed on the second surface, or at least one external groove formed in the circumferential portion, or any combination thereof, the at least one first internal groove includes a shape, in which the first surface is recessed in a direction facing the second surface, the at least one second internal groove includes a shape, in which the second surface is recessed in a direction facing the first surface, and the at least one external groove includes a shape, in which the circumferential portion is recessed in a direction facing a rotation axis of the brake disk.