Abstract
Topology Optimization has been an effective tool for weight reduction and performance design and has essential applications in automobile industry. The main objective of this paper is to design a lighter weight bell crank and brake pedal than the existing design which is generally used in the automobile parts. The newly optimized design of bell crank and brake pedal is compared with the existing design. The CAD model of the bell crank and brake pedal is modeled using SOLIDWORKS software and the analysis of the newly optimized model is carried out using the Altair INSPIRE 9.5 . Using the above methodology, a light weight bell crank and brake pedal model is designed and the FEA analysis is used for obtaining the maximum and minimum value of displacement, % of yield, tension/compression, shear stress and von mises stress on the optimized design. The results of the design reflect that the weight of the bell crank has been reduced to 140 grams which is about 24% less weight then the existing design and the optimized weight of the brake pedal is reduced from 363g to 211g.
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