Structural Optimization of the Brake Pedal Using FEA and UTM

·        In this study, the structural performance of a brake pedal was evaluated and optimized using Finite Element Analysis (FEA), topology optimization, and experimental validation. A comparative analysis between structural steel and gray cast iron revealed that structural steel provides superior stiffness with lower deformation, making it more suitable for brake pedal applications.   ·        Topology optimization was then applied to the structural steel model, resulting in a reduction in mass from 1.1364 kg to 1.0758 kg, thereby improving material efficiency. The optimized design exhibited a moderate increase in equivalent stress and deformation; however, these values remained within acceptable limits, ensuring safe operation under applied loading conditions.   ·        Experimental compression testing using a Universal Testing Machine (UTM) validated the numerical results, showing good agreement between simulation and practical performance. Minor deviations were observed due to real-world factors such as material inconsistencies and boundary condition variations.   ·        Overall, the study demonstrates that the integration of FEA, topology optimization, and experimental validation is an effective approach for developing lightweight and structurally efficient automotive components. The optimized brake pedal achieves an improved strength-to-weight ratio while maintaining safety requirements, and the methodology can be extended to the design and optimization of other critical vehicle components.

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