Dokumen - Tips - On The Correlation of A Helicopter Brake Assembly Model by

On the Correlation of a Helicopter Brake Assembly
Model by means of 3D Scanning Laser Doppler

Vibrometry
D.J. Alarcón*, Abdelbasset Hamdi**, Jean-Frederic Diebold**,
Prof. Dr. Peter Blaschke*
* Technische Hochschule Wildau, Germany

** Safran Landing Systems, France
Contents
 Motivation of the Study

 Experimental Setup
 Testing Challenges
 Results and Discussion
 Conclusions
 Further Work
 Lab Tour
Alarcón, Hamdi, Diebold, Blaschke 2

On the Correlation of a Helicopter Brake System by Means of 3D Scanning Laser Doppler Vibrometer
Motivation of the Study
Photo source : www.journal-aviation.com

In the automotive industry, brake squeal is perceived

since decades as a comfort and quality perception
issue.
Brake squeal has gained relevance during the last

years in the aviation industry, which strives to offer
more comfortable aircraft, while keeping noise levels
to a minimum.

Brake rotor and pad are made of carbon-carbon composites.

 Lightweight composite material, anisotropic

properties, non-linearly distributed damping
components.
 Phenomena like contact non-linearties and

interfacing need to be taken into account on the FE
model, to simulate a braking event.
Not straightforward FE modeling!

BLASCHKE, P., SCHNEIDER, T., Reactionless Test to Identify Dynamic Young‘s Modulus and Damping of Isotropic Plastic Materials, Topics in Modal Analysis,
Vol. 7, Proceedings of the IMAC XXXI, Garden Grove, CA, USA, 2013.

BLASCHKE, P., SCHNEIDER, T., Reactionless Test to Identify Dynamic Young‘s Modulus and Damping of Isotropic Plastic Materials, Topics in Modal Analysis,
Vol. 7, Proceedings of the IMAC XXXI, Garden Grove, CA, USA, 2013.
 Modal test - 3D SLDV + Scalable Automatic Modal Hammer

 Adjustable, repeatable excitation up to 20 kHz
 NO mass loading  NO accelerometers
 NO work piece modification  NO shakers
 High number of DOFs for FE correlation  test automatization
Experimental Setup
Scalable Automatic
3D SLDV computer & data
Modal Hammer (SAM)
management module
Work piece
Foam mat
3D SLDV scanning
Test bench vibrometer heads

Testing Challenges: Brake Caliper

Testing Challenges: Brake Caliper
 Brake caliper placed leaning against soft foam mats.

 The chosen experimental setup allows the laser scanning of the
entire structure in only one shot  reduction of testing time.
 173 tested DOFs, 18 DOFs disabled due to poor line of sight.
 SAM set to impact at the rear side of the structure, to avoid
interference in the laser scanning. The impact point is sensitive for
all vibrational modes.

Testing Challenges: Brake Disc

Testing Challenges: Brake Disc
 Brake disc hanging on elastic rubber bands.

 Setup allows the laser scanning of the entire structure in only one
experimental setup without a re-alignment of the 3D SLDV laser
heads  reduction of testing time.
 100 tested DOFs, 96 DOFs measured optimally.
 Brake disc needed to be sprayed with white developer in order to
improve the laser reflectivity.

Testing Challenges: Brake Pad

Testing Challenges: Brake Pad
 Hanging the brake pad for the

test was impractical.
 The 3D SLDV heads needed to
be realigned to fit the new
experimental setup.
 106 DOFs tested, 5 DOFs
disabled due to SAM
interference on the scanning.
 Brake pad needed to be
sprayed with white developer
in order to improve the laser
reflectivity.

Results and Discussion: Brake Caliper
* Eigenfrequencies and modal damping ommited due to confidentiality reasons.

Results and Discussion: Brake Caliper

Results and Discussion: Brake Disc

Results and Discussion: Brake Disc

Results and Discussion: Brake Pad

Results and Discussion: Brake Pad

Results and Discussion
 Established a comparison between FEA and EMA

eigenfrequencies and mode shapes.
 Good agreement on mode shapes up to the

highest modes on the bandwidth.
 Poor initial correlation between FEA and EMA

eigenfrequencies.

Conclusions
The misalignment between experimental and simulated

eigenfrequencies has two main causes:
1) an inexact input of the material properties due to complex,

non-proportional material parameters
2) the real tested geometry is different from the CAD version
used on the FEA model.
No bronze
ring
attached
Bronze ring
attached

Conclusions
Many low-frequency experimental modes are lower than their experimental

counterparts  observed mass loading effect.
𝑘
𝜔𝑛 =
𝑚
Where k is the stiffness of the system and m is the mass of the system.
The natural frequency of the system decreases with an increasing mass, in this
case, the mass loading due to the bronze ring.
No bronze
ring
attached
Bronze ring
attached

Further Work
 Update of the material and geometry parameters.
 True modal correlation procedure by means of

harmonic response analysis, of cross-MAC analysis
and, if necessary, of iterative methods.
 Commercial softwares such as FEMtools are a

useful tool for this correlation.

Further Work
 Model updating is among one of the important milestones in

squeal noise analysis methodology and problem solving
Brake squeal FE
Model Identify the coupling modes
Free-free (Not yet mature technique)
Modal Analysis of brake parts : LSDV
ping tests and FE Model Stability analysis of the
coupling modes
Frequency and Update FE
description of disc, Be in support for tests and
Model
caliper/pad modes instrumentations
Squeal noise
Microphone Squeal noise frequencies
acquisition analysis Type and
Squeal noise category of the
occurrences for n observed squeal
Braking tests on rig with braking
specified protocols to noise
produce squeal noise Confirm the frequencies of
the squeal noise Severity of
Accelerometer squeal noise
acquisition and LSDV Squeal noise problem ( level
acquisition vibration analysis and occurrence)
Nature of the
coupling modes

Lab Tour
To the TH Wildau lab

tour visitors:
We meet at 14:00 at the

TH Wildau stand here at
the exhibition.
The lab is accessible by

car with several available
parking spots.

Thanks for your attention! Questions…?
Abdelbasset HAMDI Daniel J. Alarcón Cabana
Tel. : +33 (0)1 46 29 83 88 Tel. : +49 (0) 3375 508 399

E-mail: Mobil: +49 (0) 151 267 92 815
abdelbasset.hamdi@safrangroup.com E-mail: daniel.alarcon@th-wildau.de
www.TH-Wildau.de/Maschinendynamik


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On the Correlation of a Helicopter Brake Assembly

Model by means of 3D Scanning Laser Doppler

* Technische Hochschule Wildau, Germany

 Motivation of the Study

Alarcón, Hamdi, Diebold, Blaschke 2

Photo source : www.journal-aviation.com

Alarcón, Hamdi, Diebold, Blaschke 3

In the automotive industry, brake squeal is perceived

Brake squeal has gained relevance during the last

Alarcón, Hamdi, Diebold, Blaschke 4

Brake rotor and pad are made of carbon-carbon composites.

Alarcón, Hamdi, Diebold, Blaschke 5

 Lightweight composite material, anisotropic

 Phenomena like contact non-linearties and

Not straightforward FE modeling!

Alarcón, Hamdi, Diebold, Blaschke 6

Alarcón, Hamdi, Diebold, Blaschke 7

 Modal test - 3D SLDV + Scalable Automatic Modal Hammer

Alarcón, Hamdi, Diebold, Blaschke 9

Alarcón, Hamdi, Diebold, Blaschke 10

 Brake caliper placed leaning against soft foam mats.

Alarcón, Hamdi, Diebold, Blaschke 11

Alarcón, Hamdi, Diebold, Blaschke 12

 Brake disc hanging on elastic rubber bands.

Alarcón, Hamdi, Diebold, Blaschke 13

Alarcón, Hamdi, Diebold, Blaschke 14

 Hanging the brake pad for the

Alarcón, Hamdi, Diebold, Blaschke 15

* Eigenfrequencies and modal damping ommited due to confidentiality reasons.

Alarcón, Hamdi, Diebold, Blaschke 16

* Eigenfrequencies and modal damping ommited due to confidentiality reasons.

Alarcón, Hamdi, Diebold, Blaschke 17

* Eigenfrequencies and modal damping ommited due to confidentiality reasons.

Alarcón, Hamdi, Diebold, Blaschke 18

* Eigenfrequencies and modal damping ommited due to confidentiality reasons.

Alarcón, Hamdi, Diebold, Blaschke 19

* Eigenfrequencies and modal damping ommited due to confidentiality reasons.

* Eigenfrequencies and modal damping ommited due to confidentiality reasons.

 Established a comparison between FEA and EMA

 Good agreement on mode shapes up to the

 Poor initial correlation between FEA and EMA

Alarcón, Hamdi, Diebold, Blaschke 22

The misalignment between experimental and simulated

1) an inexact input of the material properties due to complex,

Alarcón, Hamdi, Diebold, Blaschke 23

Many low-frequency experimental modes are lower than their experimental

Alarcón, Hamdi, Diebold, Blaschke 24

 Update of the material and geometry parameters.

 True modal correlation procedure by means of

 Commercial softwares such as FEMtools are a

Alarcón, Hamdi, Diebold, Blaschke 25

 Model updating is among one of the important milestones in

Alarcón, Hamdi, Diebold, Blaschke 26

To the TH Wildau lab

We meet at 14:00 at the

The lab is accessible by

Alarcón, Hamdi, Diebold, Blaschke 27

Abdelbasset HAMDI Daniel J. Alarcón Cabana

Tel. : +33 (0)1 46 29 83 88 Tel. : +49 (0) 3375 508 399

Alarcón, Hamdi, Diebold, Blaschke 28

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