Analysis of natural frequency variability of a brake component

The manufacture of automotive disc brake calipers is subjected to many inherent variabilities resulting in product variability. In particular, the dispersion of natural frequency values is a primary issue in the context of vehicle comfort. This paper aims to quantify natural frequency variability and search for its causes. Extensive experimental tests and numerical simulations, described in the paper, point out the fundamental role of mold wear and assembling process in this variability.

► Experimental modal analysis involving numerous caliper specimens.
► Statistical assessment of the natural frequency variability due to manufacturing tolerance.
► Geometric tolerance of the casting responsible for natural frequency variability.
► Important role of mold wear and assembling in the geometric tolerance of the casting.