Brake Systems

Automotive brake systems are complex mechanisms that enable a vehicle to dissipate the energy of motion as heat. Modern brake systems are designed for weight minimization, thermal efficiency and cooling, wear characteristics, and noise and vibration characteristics. A successful brake design should be lightweight, durable, wear evenly and consistently, and should not suffer from squeal, groan, or other brake noises and shakes. Achieving these numerous goals is a ongoing design challenge.

SIMULIA provides realistic simulation solutions—such as our Abaqus Unified FEA product suite, Multiphysics, simulation automation and optimization capabilities, and SLM products—that address a multitude of automotive engineering challenges. The Abaqus Unified FEA product suite from SIMULIA delivers a complete solution for brake design and simulation needs. State-of-the-art contact capabilities, material models, friction material behaviors, and loading features provide the user with a unique capability for the simulation of brake system stress for durability, heat generation, temperature distribution, and squeal. Our software contains unique functionality for brake simulation including a specialized technique for applying braking torque in the mechanically correct way without the user needing to define force couples for torque application. In addition, a high-performance complex Eigensolver and inclusion of system damping due to frictional contact eliminates the need for complicated DMAP or other programming methodology.

Solution Capabilities

• Pressure and velocity dependent frictional contact and heat generation capabilities
• Specialized procedures for applying and controlling brake pressure and torque
• Structural-thermal sequentially coupled analysis for brake system heating
• Correct inclusion of system damping due to braking for squeal calculation
• Complex Eigensolver for brake squeal analysis
• Simulation process automation
• Design optimization