Automotive disc-brake squeal noise modeling for shape optimization under uncertainties

Disc-brake systems in automotive vehicles tend to exhibit undesirable squeal noise during braking operations. Although this noise does not affect braking efficiency, it creates noise pollution and poses problems from a sales point of view since noise is commonly associated with malfunction by consumers. Squeal noise can be minimized by optimizing the shape of the system's mechanical parts. However, uncertainties related to manufacturing processes inevitably affect the system's response, and must be considered. The presented work aims at numerically quantifying and minimizing disc-brake squeal noise in the presence of uncertain parameters. A simplified disc-brake model is constructed using the novel Isogeometric Analysis method which is well-suited to shape optimization problems. The prediction of squeal noise propensity is based on the fact that squeal noise is directly related to unstable structural modes and uses Complex Eigenvalue Analysis to determine the extent of squeal occurrences. A surrogate-based optimization strategy is used to handle the high computational cost in the context of optimization, as well as to propagate uncertainties. The constructed model shows good capability for representation and quantification of squeal noise phenomena. A Pareto front of robust squeal minimizing shapes is obtained through the proposed approach.