Design and Optimization of Brakes and Pedal Assembly for FSAE race car

Optimizing the weight of pedal assembly

Final pedal assembly (Lower Mount pedal is used)

This can be done using various simulation software before fabrication of the parts.
The proper designing and stress analysis is done to optimize strength to weight ratio of the various pedals.
Brake pedal Clutch pedal Accelerator pedal

Considering various pedal on by one BRAKE PEDAL

Most stressed pedal out of three ,on this pedal max stress is produced out of three as this pedal is experiencing max force. The force in our case is 350N on the pedal (300-500N average).taking a pedal ratio of 7:1 we get 350 N force for a braking force on master cylinder is 2450N.Stress Analysis is done on ANSYS and max stress is determined for minimum possible weight

alum. design1

steel design2
alum.design2(best) steel design1

The Two material used for the ansys is mild steel and aluminium .They are selected based on density , strength, availability and machinability. Comparison is given in table
PROPERTIES/MATERIAL 1018 mild steel Aluminium alloy 6061-t6

Density(g/cc)
Young modulus(Gpa) Poisons ratio Yield strenth(Mpa) Factor of safety Max allowable stress(Mpa)

7.85
210 .27 320 3 106

2.7
68.9 .33 241 3 80.33

And the results are compared and best design is chosen the comparison is given In table below
MATERIALS Aluminium Alloy(6061 t6) PARAMETERS Max Stress(Mpa) Deformation(mm) Weight(gm) Mild steed(1018) Max. Stress(Mpa) Deformation(mm) Weight(gm) DESIGN 1 74.213 .79 110 74.261 .25 290 DESIGN 2 80.769 .66 66(Best) 80.687 .26 198

CLUTCH PEDAL
Less stressed as compared to brake pedal hence can be lighter but because of dimension constraints it has limitations of weight. The force on the clutch wire is 350N hence by having a lever ratio of 7:1 we have to apply a force of 50N only on the pedal.

Design 1

Design Design 3Design 2 4(best,chosen)

And the results are compared and best design is chosen the comparison is given In table below
DESIGN MAX STRESS(Mpa) WEIGHT(gm) Mild steel aluminium

1
2 3 4

19.57
100.84 62.192 43.558

234
311 164 138

82
110 57 48(Best)

ACCELERATOR PEDAL
This is least stressed and loaded pedal of the three. Only 20N is the force required for the throttle butterfly valve to open completely hence by taking a lever ratio of 2:1 we have to apply only 10N of force.The Various results are show in figures and table given below.

DESIGN

MAX STRESS(Mpa)

WEIGHT(gm)

Mild steel

aluminium

7.293

192

66

designDesign 2 1

8.5

115

40

RESULT & CONCLUSION Brake pedal weight is reduced by 40% as compared to average racing car (tiltin having 110g) Clutch pedal weight is reduced by 46.67% as compared to tiltin clutch pedal having 90g Accelerator pedal is made as light as possible not by stress factor but by dimension constraints and ergonomically considerations. No more reduction is possible as because of either or both reasons. Dimension and ergonomic consideration Stress consideration

FUTURE MODIFICATION BY US
Hand clutch
This will be a extension attached to the gear lever that will provide the ease of gear shifting . Providing the clutch lever in hand will also be beneficial for physically challenged people. The arrangement can be attached in any vehicle as a detachable assembly.

Kill Switch
This is a type of emergency switch employed in industries for safety purpose in case of accidents whole plant can be turned off by this switch. Same can be employed in the vehicle behind brake pedal so incase of brake failure the over travel of the pedal Triggers the switch and cuts the engine off.