Yumoto 2006
Yumoto 2006
Yumoto 2006
SAE TECHNICAL
PAPER SERIES 2006-01-0693
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2006-01-0693
and some correlation data between CAE simulation PREPROCESS AND MAIN PROCESS
results and experiments.
In the main menu window, which has three frames, we
TOOLS AND FEATURES OF THE DEVELOPED can start the modeling of a new disc, browse
DESIGN SYSTEM accumulated simulation results, and manage simulation
files as well. We define a new project in the first frame or
OUTLINE OF THE SYSTEM select an existing one from a project list, and register a
new design or select a registered one in the second
Figure 1 shows the flow diagram of CAE processes used frame. The simulation result files of the selected design
in the developed system. This system consists of two are listed in the third frame.
parts. The first part simulates the individual performance
of each design. A design engineer, without professional Table 2 lists the operations classified into manual and
knowledge or skills with CAE, can easily carry out FEA. automated ones, which are operated by our new system,
The second part is a decision-support system that in the preprocess and main process.
compares the simulation results of several alternative
designs. Table 2 Manual and automated operations in preprocess
and main process
CAE specialists, and not ordinary design engineers,
have traditionally been in charge of CAD and CAE Manual Automated Human
Step
operations. This is because special knowledge and operation operation verification
complicated operations, such as modeling, meshing, Parametric x Input x 3D-data Basic-design
and boundary conditioning, are necessary to carry out design dimension generation integrity
CAE simulation. With our new system, a meshed model x Select x 2D drawing
is created and the analysis is processed automatically Material x Mass
by inputting dimensions, vehicle specifications, and calculation
braking schedules in each operational window, and Basic- x Command x Meshed- Meshed-
clicking the execution button. model execution model model
creation creation integrity
We have developed PC-based design-support tools for Eigenvalue x Command x Full-model Results after
preprocessing and postprocessing with the analysis execution generation postprocess
MSC.Nastran™ solver. In addition, we have x Calculation
programmed application tools ourselves on the Thermal- x Input x Boundary Analysis-
Windows® platform with Microsoft® Visual Studio® and analysis condition conditioning model
structured query language (SQL). In its early stage of modeling integrity
the development, this system won the 2002 Windows Thermal x Command x Calculation Results after
Digital Engineering System Award for Encouragement analysis execution postprocess
from Nikkei Business Publications, Inc., a leading
publisher of business and technical information This system has the flexibility needed to verify the
magazines in Japan [5]. results of each operation and correct them manually if
necessary. This feature assures the extendibility for a
new disc configuration. This also prevents the design each part. Using the pull-down menu at the top of the
process in the developed system from being a black box right frame, we can select registered standard types with
for ordinary design engineers. Using the system, design various connecting parts between the hat and friction
engineers can get opportunities to obtain knowledge on plate. In addition to this sectional view, other views for a
the brake system behavior and FEA operational skills. fixing plate and ventilation passages with vanes are
available. All the dimensions of a brake disc can
Parametric Design therefore be input parametrically with this tool.
At a glance, disc configuration seems to be simple. If we select a gray-cast-iron grade from the pull-down
However, it cannot be defined as a single standard menu, disc material properties necessary for FEA, such
configuration, because its details have a diversity to as density, Young’s modulus, and thermal conductivity,
meet various customer requirements through controlling are linked to the created 3D model data. We can monitor
eigenmode alignment and thermal deflection. We the model's conformity to the weight target by using a
analyzed a lot of disc configurations, and found that the mass-calculation utility of our modeling tool in this step,
connecting part between the hat and the friction plate without using a commercial 3D-CAD system. This
causes most of the diversity. We therefore defined basic modeling tool has another utility for model data export,
standard configurations of a disc by classifying and and 3D-CAD data for a newly designed disc can be
combining the following components: easily generated. At present, our system can export
model data only to a certain commercial CAD system,
x Disc(s) for friction plate but we are going to expand this function to other CAD
x Ventilation passages with vanes and their circular systems.
periodicity
x Connecting part between the hat and friction plate in Basic Meshed-Model Generation
the shapes defined with arcs and straight lines
x Cylinder portion of hat Most commercial CAE tools have an automated mesher,
x Another disc for fixing plate with holes which mainly uses tetrahedron elements that makes
automated meshing easier. However, they are
Figure 2 shows a window for model creation by sometimes inferior to hexahedron elements in view of
parametric design tools. The left frame shows a simulation accuracy for a model that has fewer degrees
sectional view of standardized disc configurations. They of freedom to reduce calculation time. Moreover in some
are composed of various disc types, such as solid and cases, a tetrahedron element causes poorer
ventilated, drum-in-hat, and inner-hat (also known as reproducibility of meshed models that have the same
reverse-hat, inside-out, or out-board-flow) discs. basic configuration with small difference in several
Dimensions of a disc are listed in the right frame and we dimensions. Therefore, we automated the meshing
can input each dimension into designated cells in the list. operation with hexahedron elements to achieve higher
calculation accuracy and shorter processing time. We
analyzed the operational procedures of several CAE
operators, and standardized the meshing process with
the highest accuracy, least operations, and best
productivity.
Eigenvalue Analysis
Thermal Analysis
Figure 5 shows the window for displaying the results of and calculated mass of design alternatives. Even if no
the thermal-stress analysis. The postprocessor solution completely meets all the requirements, we can
automatically calculates and shows the indexes for select the second best or think of another design
evaluating thermal-performance requirements in the alternative from those reports.
lower left frame, such as the maximum stress at the
friction surface and its ratio to the acceptable strength ACHIEVEMENTS OF THE DEVELOPED SYSTEM
for the selected material. The color contouring
expressions of temperature, stress, and deflection help REDUCTION IN CAE LEAD TIME
in evaluating the thermal performance of the simulated
design. Figure 6 plots the chronological change in the average
time for an FEA case and the volume of analyses for
every half year from 1999 to 2004. An FEA case here
means one eigenvalue or thermal analysis, from model
creation to a visual report for each analysis. The
horizontal axis indicates the passage of time measured
in six-month periods, the left vertical axis indicates the
average analysis time in hours shown by dots, and the
right vertical axis indicates the number of analysis cases
shown by bar chart.
DECISION-SUPPORT SYSTEM
This system has brought about many intangible Figure 7 explains the continuous-improvement cycle of
achievements as follows: the developed brake disc design system. We have
focused on a brake disc and standardized the disc
1. The automated meshing with hexahedron elements configurations, FE modeling, and postprocessing
and boundary conditioning assures the through our accumulated experience with many CAE
reproducibility of the meshed model and the analyses and experimental results. Furthermore, we
accuracy of analysis results. We can compare all the have automated and speeded up each CAE process,
simulated results evenly with disregard to such as modeling, eigenmode identification, and final
differences among designers. evaluation of thermal-strength analysis. Figure 7 also
2. In eigenmode analysis, we can obtain a reliable reveals the following four key factors that are essential in
estimation of high-frequency mode, up to 15 kHz, by successfully establishing this system.
using a many-degree-of-freedom disc model of
50,000 hexahedron elements within reasonable x Focus on and expertise in brake disc design
processing time. x Simplicity of brake disc configuration
3. Knowledge of the effects of disc configurations, x Gradual system construction
dimensions, and material properties on resonant x Continuous improvement
frequencies and thermal deflections can be obtained
through the accumulation of vast numbers of FEAs Some of them are explained in detail in the following
and tests for validation. This makes it easier to sections.
deliberate on design alternatives. In addition, the
design system with decision support helps in
SIMPLICITY OF BRAKE DISC CONFIGURATION
selecting an optimum solution from ten design
alternatives within two days.
We defined multiple standard configurations of brake
4. An optimum solution for meeting tradeoff
discs. However, a brake disc basically consists of simple
requirements, such as squeal, judder, thermal
bodies such as a cylinder, discs and ventilation
strength, and weight reduction, can be determined at
passages. A circularly symmetric brake disc model
the early stage of the development by collating
therefore can be easily divided into simple elements.
reports of simultaneous analyses on eigenvalues
This simplicity of the disc shape makes it easier to
and thermal stress and deflection.
construct various disc configurations with a combination
of these simple elements and apply an automated
The developed design system has provided many discs
meshing algorithm systematically. Due to this simplicity,
that satisfy various requirements of most of Japanese
the coordinates of nodes in a meshed model are used
OEMs, some of them directly and others via Tier 1s.
for identifying specific nodes and elements in the
preprocess and postprocess tools.
GRADUAL SYSTEM CONSTRUCTION requirements for discs and drums in a brake system as
well as in a full vehicle under various operational
Node identification by using the coordinates described conditions. We have an integrated process for discs and
above generalizes the data transfer between CAE drums from research and development to manufacturing.
processes. This generality has exempted us from We can therefore exceed OEM or Tier 1 in terms of the
applying a complicated algorithm for numbering a great depth of our expertise focusing on brake discs and
many nodes and elements. The sequence of the CAE drums.
operational processes does not always agree with their
priority of the effectiveness of productivity improvement Through various opportunities like the SAE Annual
in each process. However, our node-identification Brake Colloquium, the brake community shares the
system makes it possible to develop system tools one accumulated knowledge on the correlation of brake
after another with disregard to the sequence of the CAE system behaviors between real-field, proving-ground,
operational processes. As a matter of fact, we chassis-dynamometer, brake-dynamometer, and test-
constructed the postprocessing tool for eigenvalue bench results. Based on this shared knowledge and
analysis first and the preprocessing tool for parametric individual information for each targeted vehicle project
model creation later. provided by OEM or Tier 1, the reliability of our
developed products is assured by CAE-simulated results,
Furthermore, we can apply old and new design systems, which are validated by test results on a brake
namely, our developed system and a commercial dynamometer and a test bench, as shown in Figure 9.
process, alternatively. For example, we can design a
new disc through the developed processes exclusively,
or we can create a meshed model with a commercial
FEA tool and then evaluate the simulation results with
the developed system.
can obtain more accurate CAE results for our discs, properties that were determined for each gray-cast-iron
because we use the material properties of the castings grade but not modified them in each analysis on different
that we cast mainly in our in-house foundry and measure discs.
some of the properties by ourselves. Consequently, we
can provide the highest design quality at the early stage Table 4 Material and foundry of discs for Figs. 10 and 11
of new vehicle development without need for a state-of-
the-art complex eigenvalue analysis [9-11] or nonlinear Material FC190 JIS FC250 SAE G3000 Total
analysis [1]. JP 16 9
Foundry 27
US 2
EIGENVALUE ANALYSIS
BASIC STRENGTH
THERMAL ANALYSIS
according to benchmarked data of brake discs from Technical Report, No. 21 (2003), pp.180-185 (in
Japan, the USA, and Europe [17]. We are continuously Japanese)
accumulating benchmarking data and studying the 5. NIKKEI DIGITAL ENGINEERING, No. 60
following trends: (December 2002), pp.96-107 (in Japanese)
6. A. Fukano et al., Development of Disc-Brake Design
x Basic configurations such as inner or ordinary hat, Method Using Computer Simulation of Heat
and straight or spiral vanes; Phenomena, SAE Paper 860634
x Disc size and mass versus vehicle specifications 7. J. Brecht et al., Influence of Material Selection on
such as maximum speed and gross vehicle weight. Stresses in Ventilated Brake Discs, SAE Paper
980595
We are taking these trends into consideration and 8. A. Jerhamre et al., Numerical Study of Brake Disc
incorporating new configurations into our system. As a Cooling Accounting for Both Aerodynamic Drag
result, we will continue providing brake discs with Force and Cooling Efficiency, SAE Paper 2001-01-
competitive performance in a short development lead- 0948
time by utilizing the new design system described here. 9. H. Ouyang et al., On Automotive Disc Brake Squeal
- Part II: Simulation and Analysis, SAE Paper 2003-
CONCLUSION 01-0684
10. T. S. Shi et al., Advances in Complex Eigenvalue
We have constructed an original brake disc design Analysis for Brake Noise, SAE Paper 2001-01-1603
system, by standardizing, automating, and speeding up 11. A. Bajer et al., The Influence of Friction-Induced
each CAE process. The main achievements of this
Damping and Nonlinear Effects on Brake Squeal
system are summarized as follows.
Analysis, SAE Paper 2004-01-2794
12. Y. Jimbo et al., Development of High Thermal
1. An optimum and robust design can be selected from
Conductivity Cast Iron for Brake Disk Rotors, SAE
many alternatives quickly and easily.
Paper 900002
2. The lead time to find an optimum solution is reduced
13. S. Sakamoto et al., Development of High Cooling
to two days, and the design quality is improved at
Performance A New Brake Rotor, TOYOTA
the early stage of development, through continuous
Technical Review, Vol. 44, No. 1 (May 1994), pp.90-
improvement of CAE processes.
95 (in Japanese)
3. Knowledge of the effects of disc configurations,
14. T. Shimazu et al., Development of A New Brake
dimensions, and material properties on resonant
Rotor with Improved Cooling Capacity, JSAE
frequencies and thermal deflections can be obtained
Review, Vol. 25, No. 3 (July 1994), pp.128-133 (in
through the accumulation of vast numbers of FEAs.
Japanese)
4. A design methodology was established to satisfy the
15. C. Repmann, Investigation of the Thermal Behaviour
requirements for a brake system, such as squeal,
of Vented Disc Brakes by Means of CFD, Advanced
judder, and thermal strength, by improving the
Brake Technology, 2003, pp.51-75
simulation accuracy of eigenvalue and thermal
16. T. Chatterley et al., Cast Iron Brake Discs - Current
analyses with conventional CAE methodology.
Position, Performance and Future Trends in Europe,
SAE Paper 1999-01-0141
We will continuously improve this system by automating
17. T. Okamura et al., High-Precision Brake Discs to
the final decision making, applying sophisticated CAE
Reduce Judder, SAE Paper 2005-01-3924
methodology like nonlinear analysis, and constructing a
design system for brake drums.
CONTACT
REFERENCES
Hiroyuki YUMOTO, KIRIU Corporation
2, Omata-Minami, Ashikaga-shi, Japan 326-0142
1. T. Valvano et al., An Analytical Method to Predict
E-mail: h-yumoto@kiriu.co.jp
Thermal Distortion of a Brake Rotor, SAE Paper
URL http://www.kiriu.co.jp/
2000-01-0445
http://www.kiriu-usa.com/
2. Y. Takahashi, et al., Establishment of an Intake Port
Design Support Tool Using CFD, Honda R&D
Technical Review, Vol. 15, No. 1 (April 2003),
pp.103-108 (in Japanese)
3. T. Uchida, et al., Practical Examples and Future
Directions for CAE-Based Development for
Automobile Transmissions by Designers, Honda
R&D Technical Review, Vol. 15, No. 1 (April 2003),
pp.109-114 (in Japanese)
4. H. Yokohata et al., Development of "PT-CS": CFD
Analysis System for Design Engineers, Mazda