Simulation Driven Design of Brakes for Electric and Internal Combustion Vehicles

ABSTRACT

The brake system is a critical part of vehicle architecture. Brakes must slow down or stop a vehicle whenever needed. A good brake system design will ensure reliability, durability, efficiency, performance, and safety where and however the vehicle is operated. If a design is inadequate, the vehicle operation may be unsafe. Customers expect a quiet, durable brake system that performs as expected with predictable maintenance during service life. Moreover, brake operation is increasingly controlled through regulations that call for prediction of performance over a standard brake duty cycle. Manufacturers must be able to accurately predict brake performance at an early development phase to avoid expensive overdesign or late-stage design changes, and to reduce or eliminate expensive prototype testing.

SIMULIA provides comprehensive solutions for brake system design and performance validations with simulation-ready models at various scales and levels of fidelity starting from systems level modeling emanating from vehicle architecture to high fidelity physics based modeling leveraging FEM and CFD based methods. These validations also range from full vehicle level to sub-system level. This enables you to not only identify problem areas, but provide design recommendations that eliminate the problems. Rapid turnaround time for model setup, simulation, visualization, and design modification enables you to quickly make design changes to the baseline and evaluate the improvements in brake performance. Perform rapid design for a wide range of vehicle operating conditions and braking cycles.

Highlights

• Design brake systems and surrounding features to provide adequate cooling air flow to prevent overheating of pads, rotors, and nearby components such as wheel and tire sensors
• Perform structural and thermal analyses to increase brake system life and reduce unwanted noise from brake groan & squeal
• Utilize advanced particle tracking to prevent water from degrading stopping distance and limit unwanted effects from brake dust deposition
• Reduce physical testing needs and prevent expensive late stage brake system changes by evaluating and optimizing multidisciplinary trade-offs early in design stage