Abstract
This paper proposes a design optimization method for disc brake systems that specifically aims to reduce brake squeal, with robustness against changes on contact surface pressure distribution, based on the concept of First Order Analysis. First, a simplified analysis model is constructed in which a pressure distribution parameter is introduced, and the relationships between the occurrence of brake squeal and the characteristics of various components is then clarified, using the simplified model. Next, a new design performance measure that takes pressure distribution changes over the contact surfaces into account is proposed for evaluating brake squeal performance, and an optimization problem is formulated in which this performance measure is used as a constraint condition, with maximization of the brake-pad contact area as the objective function. The optimization problem is solved using a genetic algorithm. The proposed method is then applied to design problems and a disc brake system is constructed based on an optimal solution. Finally, experimental studies are conducted to confirm that the proposed method can yield optimal designs that minimize brake squeal and are robust against pressure distribution changes.
