Brake Pedal Optimization

The brake pedal optimization is done using HyperMesh-optistruct-Topology optimization.

The brake pedal in automotive are mainly made up of Casting, Sheet metal & alloys of metals,
here is an example of a steel plate brake pedal which is having a thickness of 7 mm, and need to be optimized with a 2 mm thick plates on both sides along its longitudinal axis.

first the analysis was done on the 7 mm thick steel plate & found the stress & deformation over the plate, then to optimize the loading conditions, Topology optimization is used to reduce the unwanted material over the plate & found the thickness t be 5 mm.

To further optimize the plate, design was made in sheet metal plate of 5 mm thick on both sides along its longitudinal axis & run with topology optimization to get the thickness reduced to the desired value of 2 mm thick.

The analysis in HyperMesh-optistruct-topology optimization is carried out first to define the material properties then loads & boundary conditions also the two plates are join together using spot welded with the CWELD elements. & the optimization was carried out.

The brake pedal is optimized to with stand the load of 2295 N, with a 2 mm thick plate.
Further more it can be optimized to get the thickness of 1.2 mm thick, adding alloys & removing the unwanted material to give it a complicated design & ergonomics.