Finite Element Simulation of an Automotive Brake Rotor With Metallic Damping Inserts

A finite element method is developed for simulating the performance of an automotive brake rotor with metallic inserts that are used to dampen the vibration and radiated noise response. The metallic inserts are located in slots that are cast at the edge of the rotor circumference between the two rotor surfaces. Three different rotor configurations are evaluated: (a) an undamped solid rotor, (b) a damped rotor with an unconstrained press-fit metallic insert, and (c) a damped rotor with a constrained cast-in coated metallic insert. Comparisons of the predicted versus measured rotor surface vibration and radiated sound pressure are made to evaluate the effect of the insert and the accuracy of the finite element method. The comparisons show that significant modal damping of the rotor vibration and radiated noise can be achieved through the use of the coated metallic insert. A methodology is developed and applied to evaluate the damping of different metallic inserts and coatings from only the radiated sound pressure response.