Box-Behnken 실험설계법과 반응표면분석법을 이용한 자동차 브레이크 디스크 로터 최적설계 연구
A study on the optimal design of automotive brake disc rotor using Box-Behnken design and response surface method
1
조회
0
다운로드
0
인용
0
참고문헌
키워드
초록
본 연구에서는 자동차용 브레이크 디스크 로터(automotive brake disc rotor) 제품에 대한 시장의 높은 성능 요구 도에 대응하기 위해 유한요소해석법(Finite element Method, FEM)과 실험계획법(design of Experiments, DoE)을 이용하여 최 소 실험조건에 의한 설계 변수와 디스크 동적 특성과의 상관성을 분석하여 영향도가 큰 설계변수를 선정하였으며, BBD(Box-Behnken Design) 실험설계법과 반응표면분석법(Response Surface methodology, RSM)을 적용하여 브레이크 디스 크 로터의 벤트 비율(vent_ratio), 냉각핀(cooling fin) 형상변수, 언더컷(undercut) 형상 두께와 언더컷 각도 등의 4가지 변수 를 대상으로 4 요인 3 수준 실험설계와 분석을 통해 브레이크 디스크 로터의 동적 성능과 밀접한 설계인자와의 상관성를 예측할 수 있는 높은 신뢰성의 최적설계를 위한 설계예측회귀모델을 도출하였다. 본 연구에서는 BBD법과 RSM법을 적용 하여 18인치 디스크 로터의 설계-성능 분석과 21인치 브레이크 디스크 로터 신제품 개발을 위한 설계예측회귀모델 적용을 통해 FEM 대비 3% 이내의 신뢰성 있는 성능예측을 수행함으로써 설계기간단축과 설계변수와 스퀄노이즈(squeal noise) 발 생과 밀접한 디스크 로터의 동적 성능 간의 상관성을 규명하였다. 현재, 자동차산업분야에서는 소비자의 높은 감성 품질 요구를 만족시킬 수 있으면서도 효과적인 개발기간단축을 위한 설계개발체계 확립을 지속적으로 추진중이며, 향후 연구 결 과를 현업에 적용하여 제품 경쟁력 향상에 활용하고자 한다.
Abstract
In this work, finite element method (FEM) and design of experiment (DoE) were used to design variables based on minimum experimental conditions to cope with the market’s high performance requirements for automotive brake disk rotor products. By applying the Box-Behnken Design (BBD) experimental design and the Response Surface methodology (RSM), a four-factor, three-level experimental design and analysis were conducted on four variables, including the vent ratio, cooling fin shape, undercut shape thickness, and undercut angle of the brake disc rotor. A design prediction regression model for the optimal design with high reliability that can predict the correlation with design factors closely related to the dynamic performance of the brake disc rotor was derived. In this study, the BBD method and RSM method were applied to analyze the design and performance of an 18-inch disc rotor, and a design prediction regression model was applied to develop a new 21-inch brake disc rotor, and a reliable performance prediction within 3 % compared to FEM was performed to shorten the design period and identify the correlation between the design variables and the dynamic performance of the disc rotor, which is closely related to the squeal noise generation. Currently, the automotive industry is continuously promoting the establishment of a design and development system to effectively shorten the development period while satisfying the high emotional quality needs of consumers, and aims to improve product competitiveness by applying the results of this research to the field.
참고문헌 (13)
- 2023 Global automotive consumer study, key findings: global focus, "Deloitte", Deloitte Development LLC, ~ (2023)
- S.M. Jeon, "Design optimization of a brake disc considering frictional clamping conditions", Transactions of KSAE, pp.1739~ (2011)
- C. Kim, "Analysis of low-frequency squeal in automotive disc brake by optimizing groove and caliper shapes", Int. J. Precis. Eng. Manuf, 19, pp.505~ (2018)
- J.N. Reddy, "Finite element method" (1993), McGraw Hill
- K.J. Bathe, "Finite element procedures" (1996), Prentice Hall
- A.I. Khuri, "Response surface methodology", WIREs Comp Stats, 2, pp.128~ (2010)
- S. C. Ferreira, "Box behnken design : An alternative for the optimization of analytical methods", Anal. Chim. Acta, 597, pp.179~ (2007)
- Factorial effect analysis of material and dimensional properties of brake discs for reducing variation in natural frequencies, "T. Okamura", SAE, ~, pp.2008-01-2533 (2008)
- C.G. Seo, "Optimization of natural frequency and minimization of frequency variation on OPD", IPC vibrational mode of ventilated disc rotor, Kyungpook National University, 2015
- B. C. Song, "Structural design of a circumferential friction discbrake, considering thermoelastic instability", J. Korean Soc. Manuf. Process Eng, 6, pp.38~ (2007)
- P.A. Meehan, "On the mechanisms, growth, amplitude and mitigation of brake squeal noise", Mech. Syst. Signal Process, 152, pp.231~ (2021)
- A. Priftis, "Multi-objective robust early stage ship design optimisation under uncertainty utilising surrogate models", Ocean Eng, 197, pp.352~ (2020)
- C. Liu, "Application of improved RSM in the optimization of automotive frontal Crashworthiness", J. Transp. Technol, 6, pp.155~ (2016)