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    Synopsis-Brake Pedal

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    rock star
    This document describes a study to optimize the design of a brake pedal through topology optimization and finite element analysis. The existing brake pedal design will be modeled in CATIA V5 and analyzed under tensile loading using FEA software and strain gauge testing. Topology optimization will be used to minimize the weight of the brake pedal by removing excess material from low stress regions. The results of the FEA and experimental testing will be compared to validate the optimized design. The goal is to create a lighter and more flexible brake pedal design.

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    Synopsis-Brake Pedal

    Uploaded by

    rock star
    36 views4 pages
    This document describes a study to optimize the design of a brake pedal through topology optimization and finite element analysis. The existing brake pedal design will be modeled in CATIA V5 and analyzed under tensile loading using FEA software and strain gauge testing. Topology optimization will be used to minimize the weight of the brake pedal by removing excess material from low stress regions. The results of the FEA and experimental testing will be compared to validate the optimized design. The goal is to create a lighter and more flexible brake pedal design.

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    SYNOPSIS-BRAKE PEDAL

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    This document describes a study to optimize the design of a brake pedal through topology optimization and finite element analysis. The existing brake pedal design will be modeled in CATIA V5 and analyzed under tensile loading using FEA software and strain gauge testing. Topology optimization will be used to minimize the weight of the brake pedal by removing excess material from low stress regions. The results of the FEA and experimental testing will be compared to validate the optimized design. The goal is to create a lighter and more flexible brake pedal design.

    Copyright:

    © All Rights Reserved
    Download as DOCX, PDF, TXT or read online from Scribd
    Download as docx, pdf, or txt
    36 views4 pages

    Synopsis-Brake Pedal

    Uploaded by

    rock star
    This document describes a study to optimize the design of a brake pedal through topology optimization and finite element analysis. The existing brake pedal design will be modeled in CATIA V5 and analyzed under tensile loading using FEA software and strain gauge testing. Topology optimization will be used to minimize the weight of the brake pedal by removing excess material from low stress regions. The results of the FEA and experimental testing will be compared to validate the optimized design. The goal is to create a lighter and more flexible brake pedal design.

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    © All Rights Reserved
    Download as DOCX, PDF, TXT or read online from Scribd
    Download as docx, pdf, or txt
    of 4

    ABSTRACT

    Brake pedals are widely used in all automotive, which acts as a linkage between occupant and
    brake mechanism. Existing design seems to be overdesigned as per requirement FEA will be
    used to apply cantilever load Opti struct solver will be used to perform topology
    optimization. The model of an existing brake pedal was generated using CATIA V5 solid
    modeling. Existing design will be tested using strain gauge technique at tensile loading using
    UTM machine. Comparative analysis will be done with FEA and Experimental units.
    Conclusion and future scope will be suggested.
    Keywords— Brake Pedal, ANSYS, Universal testing machine (UTM), Finite Element
    Analysis (FEA).
    1. INTRODUCTION

    In recent year, the material competes with each other for existing and new market. Brake
    pedals used by driver of a vehicle to operate the brakes. The brake system in car is a
    sealed hydraulic system and relies on close tolerances between the brake shoes and drums
    or brake pads and rotors. It is one of the most significant systems of a vehicle. It has some
    basic roles, it should slow a moving vehicle, It needs to hold a vehicle stationary when
    stopped, It should bring a vehicle to a stop.

    Fig 1 Brake Pedal

    Brake pedal of TATA STORME is used as component for study. CAD Model of brake pedal
    is developed in 3D modeling software CATIA V5. In optimization design of brake pedal, a
    weight should be minimized. In automobile industry, mass of weight reduction is becoming
    important issue. To reduce the material, Topology optimization is used. Optimization is
    reducing the weight and cost of product. In automobile industry, it is obligatory to look for
    cheap & lightweight materials and which should be easily accessible. At present, brake
    pedals are made from metal but accelerator pedals and composite clutches are successfully
    utilized in automotive vehicles. This study is concentrated on variable-material for the
    conceptual design brake pedal profile.
    PROBLEM STATEMENT:
    Automotive parts like brake pedal hard to operate and not flexible. To overcome this problem
    modelling of pedal will be done in CAD & analyzing in CAE for induced stresses &
    deformation. Excess material will be search by region having less stresses & that region will
    be cut & again optimized model is analyzed for comparison with experimental test results.

    OBJECTIVE

    1. To prepare CAD design of brake pedal using CATIA V5.


    2. To study Topology optimization of brake pedal.
    3. To perform Topology optimization analysis of brake pedal by using FEA.
    4. Experimental stress analysis of brake pedal using Strain gauging & load applied
    through UTM

    5. Comparative analysis between FEA & Experimental results.


    3. METHODOLOGY

    Analysis & Optimization

    Experiment FEA

    Brake pedal 3D Part Modeling

    Machining For Optimized Material Assembly

    Fixture Preparation Material & Property

    Discretization (ie. Meshing)


    Strain gauging & UTM Testing

    Boundary Conditions (Loads,


    Data Collection Constraints)

    Results- Stress & Strain Plots

    Topology Optimization (Removal


    Of Material)

    Results- Stress & Strain Plots

    Comparision & Conclusion

    Fig 2 Flowchart of the methodology of the project

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