Numerical model for prediction of brake judder due to wear and rust

The research data in the present study included customer satisfaction reports provided by J.D. Power and auto maintenance records from all maintenance service centers in Taiwan. According to maintenance service centers, the consumers’ complaints ratio about brake judder was the highest of problems encountered in the first 5000 km but declined gradually with longer mileage to a constant ratio. After careful examination, it was found that variations in the thickness of brake discs caused by wear and rust were the main reason for brake judder. We have established a numerical model to simulate the variation of disc thickness in the time domain and further devised a formula to predict the complaint ratio. Two crucial and feasible variations—storage days and consumer driving days were proposed to predict the complaint ratio. The accuracy of the prediction value was as high as 80%. Furthermore, the formula could be applied to all types of vehicles, which is meaningful in improving the quality and performance of vehicles.