The choice of brake friction materials varies per application, but each must have the appropriate coefficient of friction and be able to disperse large amounts of heat without adversely affecting braking performance. This seminar will be an introduction to brake lining raw materials and formulation, manufacturing, quality control and testing. The course covers the critical elements that must be reviewed before arriving at a lining selection decision.

Different classes of friction material, their effects on NVH, Wheel Dust and Environment and their use will be defined.

Objective: Raise awareness, provide societal and technical background, introduce key concepts, and provide examples of test methods, testing systems, and test results for non-exhaust emissions using laboratory methods.

This course introduces the basics of automotive brake systems to graduate-level engineers who have little or no experience of the industry. It covers basic vehicle braking dynamics and the design, manufacture and operation of traditional friction brakes as well as alternative means of vehicle retardation such as regenerative braking. It also introduces students to modern electronic braking systems and current legislation. Finally, it details brake design and analysis approaches including consideration of NVH issues. The course will be delivered by academic and industrial experts with many years of experience in automotive braking systems.

- Current and innovative materials since the age of modern asbestos-free Friction Material.
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Factors influencing disc corrosion, stiction characterization and relevant methodology.

- Investigation of Creep Groan phenomena and how to overcome it.
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Cold & Hot Judder, Disc Thickness Variation (DTV) and their consequences on vehicle braking.

- Contributing factors to Judder & DTV. 

Module 1: Brief Review of Brake Noise Most Common NVH Problems

Module 2: Brake NVH Investigation and Reduction

Module 3: Squeal

- Quiz
- 
Full Braking System Modal Testing (Example)

Module 1: Introduction to NVH Introduction to Acoustics

Module 2: Introduction to Brake NVH South/Path/Receiver Model Common Brake Noises

Module 3: Dynamometer NVH Testing Different Types of Brake NVH Dynamometers
Module 4: Vehicle NVH Testing Chassis Dynamometer Testing LACT Test SAE J2625 

Module 5: SAE Brake NVH Standards SAE J2786

1. Basic Physics of Brake NVH
2. Theories of Brake Noise Definition & Mechanisms
3. Methodologies for Investigating Brake Noise
4. CAE Methodologies for Brake NVH Prediction

Module 1: Advanced CAE Methodologies: Simulations of Contact Interfaces
Module 2: Advanced CAE Methodologies: Damping in CAE
- Module 2.1 Brake System NVH Analysis with Damping
Module 3: Advanced CAE Simulations: Co-simulation

Block 1: Friction – current knowledge about the phenomenon
- Definition & Laws
- On types of friction and factors with significant impact on friction
- Measurement of friction and testing friction devices
- Friction induced vibration and noise
- Modeling friction
Block 2: Wear & Wear Mechanisms
- Definition
- Wear & environment
- Modeling wear

Product Liability prevention is a very critical element of Brake and Chassis Control Systems. Designing systems that minimize Failures and in the event of failure have a predictable, progression of failure to minimize risk and damage to the user and surroundings.

Brake System Design for Passenger Cars and Light Trucks.  A course taught from the System Perspective, focusing on the critical System Level Requirements for Brake System Design, the selection of key technology solutions of all elements of the Brake System and the Critical System Sizing Evaluation that is necessary to size the critical brake components for a particular vehicle application.

Launch Management can be viewed as the glue that holds an organization together and drives for the
common good of the project. Launch Management has a key role in ensuring that the Business strategies and objectives are aligned and have the best chance for success. The Launch Management team works with all departments, cross plant and cross region to help ensure alignments, eliminate redundancies, and avoid strategic diversions. Whether at the strategic phase, the acquisition phase, the development phase, or through the life cycle of the product or system, Launch Management has roles and responsibilities in all these phases.

How many times have you heard or been tasked to reduce cost, defects, lead time, inventory, space, and waste? With a keen eye on identifying and reducing non-value add activity; we can increase productivity and on-time delivery. So often organizational set-ups negatively impact Customer satisfaction, profit, customer responsiveness, capacity, output and quality. With a culture based on lean principles these barriers can be dramatically reduced.

Tribology is the science and engineering of interacting surfaces in relative motion. The impact of tribology in engineering systems is undeniable. Only about 22% of the fuel energy finds its way to the driving wheels while 33% of the energy dissipated only dye to frictional losses among which braking friction contributes to 5% of the frictional losses. Effective tribological performance of engineering components could lead to better fuel economy and improved lifetime of engineering components. In addition, understanding tribology and applying the knowledge in designing engineering components could delay/inhibit premature failures of engineering systems.

- Part 1 deals in depth with regenerative braking functionality, the underlying software functionality, and limitations.
- Part 2 aims to discuss how tuning of regenerative brakes can be undertaken, in the context of an active vehicle program, as well as major pitfalls and how problems can be overcome
- Part 3 examines how to verify and validate regenerative systems
- Regenerative Brakes Testing Resources provided to delegates

- Brake Vehicle Testing and Validation
- Brake Durability Testing on Vehicle
- NVH, General Concepts
- Brake Squeal: a practical approach to problem solving based on testing and CAE
- Brake Judder: a practical approach to problem solving based on testing
- Brake Groan: a practical approach to problem solving based on testing and CAE
- Brake Design Process
- Brake Pedal Feel Prediction and Optimization through 1D Calculations

Statistical Method for Caliper Fatigue

Statistical methods for brake corners and components using ISO 5725 statistical methods.

Application example for caliper and hydraulic component fatigue per SAE J2995