Review of model updating processes used for brake components

G. 1,3
Martin , E. 1,3
Balmès , G. 1
Vermot-des-Roches , T. Chancelier 2
1SDTools, 2Chassis Brakes International, 3Arts et Metiers ParisTech/PIMM

Updating protocol Test Case

Component 1 geometry Component 1 model Assembly model
Drum brake plate with fixed-point
and cable guide
FEM Geometry
• Catia Topo corr
• Reconstruction
Geometry updating Material parameters
Test geometry
• Reconstruction • Density
• COMET
• or Morphing • Young modulus

Topo corr
Contact properties
Measurements Identification Shape correlation
Material
• IDRC • MAC
parameter • Surface
• Laser • IDRM • Quality (MACErr)
updating • Pressure
• Accelerometers • Quality • Frequency Err
• Stiffness
• Step 1 : Geometry updating (Plate)
Updated Component 2 model
• Step 2 : Component parameters
Topo corr
updating (Plate)
Assembly Identification Shape correlation
measurements • IDRC • MAC
Contact • Step 3 : Contact parameters
Properties
• Laser • IDRM • Quality (MACErr)
updating
updating (cable guide – fixed point)
• Accelerometers • Quality • Frequency Err

Nominal FEM Geometry updating (Plate) Component parameters updating (Plate)

180.000 Nodes Correlation : Collocated transfer identification
• Assuming modes (accelerometers)
• Up to 2mm of distance between come ordered
Nominal Geometry and measured point • Density updated from
Error MAP STL/Nominal cloud FEM volume and
physical part weight
• The volume of the reconstructed • Relative error in
geometry if 11% lower than the volume frequency (no shapes) :
of the Nominal model
∆𝑓𝑖
Point Cloud (STL) 𝐽 𝐸 = 𝑚𝑒𝑎𝑛 (𝐸)
240.000 Points Error MAP STL/Reconstructed 𝑓𝑖

• Updated geometry leads to

Reconstructed FEM a lower error than Nominal
geometry

• A bias in model
parameter occurs if we do
not update geometry first

Test/Assembly correlation (Plate + Cable Guide) Contact parameters updating

Assembled Updated Laser Measurement Shape Correlation
Contact Property updating
Components 300 Points Identification of transfers
Stiffness chosen for the first
cable guide bending mode to
be close in frequency with the
Shape Correlation
experimental modal analysis
Contact classically defined as a
node to surface constraint Surface sets definition

Topology Correlation
ICP algorithm Updating contacts using
Surfaces or Stiffness

No optimization Optimization
mean error = 1.14 mm mean error = 0.82 mm
std error = 0.88 mm std error = 0.58 mm
max error = 5.34 mm max error = 3.01 mm
Observability matrix building
• No Mode crossing
• Mode crossing
• One test modeshape fully • Using surfaces leads to threshold effects and • MAC matrix fully diagonal
uncorrelated several full model resolution : long time
• One FEM modeshape fully • Using reduced model with stiffness on the • All values above 83%
uncorrelated surface is fast, fairly equivalent and smoother
• Many correlated below 70%

Conclusion
• Efficient & systematic updating process
• Geometry & contact : keys to good results