Optimum Design Of Brake Pedal Using Topology Optimization Method Intended For Weight Reduction On The Formula SAE Car

In this study, structural optimization of a brake pedal is carried out to reduce the component weights for the Formula SAE vehicle, with compensatable costs. Brake pedals are designed to comply with the rules set by the Formula SAE competition committee. In the brake pedal design, aluminium 7075-T6 material is chosen because of its lightweight, technical features and cost advantage. Topology optimization has been done to provide the best design of the brake pedal. The material distribution method is chosen in topology optimization. As the first step of topology optimization, the design volume is created and optimization conditions are defined. For the topology optimization, the design area is the design variable, stress is constraint and weight is the aim of optimization is defined. New brake pedal design has been created within topology optimization and production constraints. The new design is 11% lighter than the first design. For the purpose of reducing the vehicle weight, the cost increase rate is regarded as compensatable because the weight reduction is the priority criterion. Although the stress value is increased by 6%, this value is much lower than the constraint value and strength is in the desired values. At the same time, the displacement value decreased by 5%