Frictional and dynamic responses of brake pad materials, when sliding on brake disc counterfaces, are at the origin of noise, vibration and harshness (NVH) issues such as brake noise emissions. In more detail, groan is a low frequency noise emission often associated to the stick-slip frictional response of the brake system. The instability of such contact is the result of the coupling between the system dynamics and the frictional response of the materials in contact. In this work, an experimental approach is proposed for measuring the frictional response and the propensity to generate stick-slip of different lining materials, coming from commercial brake pads, when sliding on a worn surface of a brake disc, under the same controlled boundary conditions. The proposed methodology allowed for comparing the propensity of the tested pad materials to stick-slip vibrations, which is in agreement with feedback from automotive industry on groan emission.

Modeling of frictional contact systems with high accuracy needs the knowledge of several contact parameters, which are mainly related to the local phenomena at the contact interfaces and affect the complex dynamics of mechanical systems in a prominent way. This work presents a newer approach for identifying reliable values of the normal contact stiffness between surfaces in contact, in both sliding and sticking conditions. The combination of experimental tests, on a dedicated set-up, with finite element modeling, allowed for an indirect determination of the normal contact stiffness. The stiffness was found to increase with increasing contact pressure and decreasing roughness, while the evolution of surface topography and third-body rheology affected the contact stiffness when sliding.

Unstable friction-induced vibrations are considered an annoying problem in several fields of engineering. Although several theoretical analyses have suggested that friction-excited dynamical systems may experience sub-critical bifurcations, and show multiple coexisting stable solutions, these phenomena need to be proved experimentally and on continuous systems. The present work aims to partially fill this gap. The dynamical response of a continuous system subjected to frictional excitation is investigated. The frictional system is constituted of a 3D printed oscillator, obtained by additive manufacturing that slides against a disc rotating at a prescribed velocity. Both a finite element model and an experimental setup has been developed. It is shown both numerically and experimentally that in a certain range of the imposed sliding velocity the oscillator has two stable states, i.e. steady sliding and stick–slip oscillations. Furthermore, it is possible to jump from one state to the other by introducing an external perturbation. A parametric analysis is also presented, with respect to the main parameters influencing the nonlinear dynamic response, to determine the interval of sliding velocity where the oscillator presents the two stable solutions, i.e. steady sliding and stick–slip limit cycle.

Modelling interface interaction with wave propagation in a medium is a fundamental requirement for several types of application, such as structural diagnostic and quality control. In order to study the influence of a pressure-dependent interface stiffness on the nonlinear response of contact interfaces, two nonlinear contact laws are investigated. The study consists of a complementary numerical and experimental analysis of nonlinear vibrational responses due to the contact interface. The laws investigated here are based on an interface stiffness model, where the stiffness property is described as a nonlinear function of the nominal contact pressure. The results obtained by the proposed laws are compared with experimental results. The nonlinearity introduced by the interface is highlighted by analysing the second harmonic contribution and the vibrational time response. The analysis emphasizes the dependence of the system response, i.e., fundamental and second harmonic amplitudes and frequencies, on the contact parameters and in particular on contact stiffness. The study shows that the stiffness–pressure trend at lower pressures has a major effect on the nonlinear response of systems with contact interfaces.