Response Surface Methodology-Based Optimisation of Finite Element Model Updating for Disc Brake Dynamic Behaviour: A Review

Abstract

Accurate modelling and prediction of disc brake dynamic behaviour are essential for addressing vibration and noise issues in automotive braking systems. Finite element model updating (FEMU) has been widely adopted to improve the correlation between numerical simulations and experimental modal data; however, conventional updating approaches are often limited by iterative trial-and-error procedures, high computational cost, and insufficient consideration of parameter interactions. In recent years, Response Surface Methodology (RSM) has emerged as a promising surrogate-based optimisation technique to enhance the efficiency and robustness of FEMU frameworks. This paper presents a comprehensive review and synthesis of RSM-based optimisation approaches integrated with FEMU for disc brake dynamic analysis. Key developments in surrogate modelling, design of experiments, and hybrid optimisation strategies are critically examined, with particular emphasis on their capability to manage high-dimensional parameter spaces and complex nonlinear phenomena such as frictional contact and thermo-mechanical coupling. The role of advanced experimental modal analysis techniques in improving model fidelity and supporting optimisation accuracy is also discussed. Based on the reviewed literature, current limitations and research gaps are identified, including challenges related to nonlinear behaviour modelling, experimental–numerical integration, and automation of optimisation workflows. Finally, future research directions are outlined, highlighting the need for comprehensive, adaptive, and multi-physics RSM–FEMU frameworks to support reliable, efficient, and sustainable disc brake design and analysis.