Bifurcation in Stick–Slip-Induced Low-Frequency Brake Noises: Experimental and Numerical Study

The term honk noise describes a low-frequency brake noise from approximately 400 Hz to 500 Hz which arises at extremely low speeds and low brake pressures. Manoeuvres like slowly releasing the brake at a hill or gently braking against the drag torque of an automatic gearbox lead to honk noise. Under the same conditions, we observed creep groan at about 80 Hz. It has been shown that honk noise usually occurs after or alternates with creep groan. For this reason, it is assumed that honk noise—like creep groan—is a stick–slip-induced phenomenon and therefore shows highly nonlinear behaviour. In this paper, we present an approach for explaining the onset of honk noise under stick–slip excitation. A minimal model consisting of coupled mass oscillators excited by stick–slip is investigated. The model was able to reproduce the phenomena observed in the experiments. Thus, it is suitable for explaining the mechanisms leading to honk and estimate the influence of basic parameter variations. The lessons learned are a crucial step towards more realistic finite element or multi-body simulation methods, which have high potential for saving costs in the noise, vibration, and harshness (NVH) development process of brake systems.