Professor of School of Engineering, Design and Built Environment, Western Sydney University, Australia. His research interests cover Industry 4.0, Additive Manufacturing, Advanced Engineering Materials and Structures (Metals and Composites), Multi-scale Modelling of Materials and Structures, Metal Forming and Metal Surface Treatment.
Abstract—In recent years, the conventional brake, accelerator and clutch pedals of automotive vehicles
are replaced by polymeric-based composite pedals. The purpose of replacement from metallic
pedal to polymeric-based composite material is to reduce the weight, cost and improve material
degradation by corrosion. In this paper four different sections of polymeric based brake pedals
are analyzed as per the design parameters received from General motors. The sections are
analyzed and arrived at a winning concept based on stiffness comparison. A full scale model is
developed from the winning concept, while developing full scale model an ergonomic study has
been made on few hatch back and SUVs car’s to improve the driver’s comfort and reduce
fatigue due to breaking operation. The pedal is modelled using CATIA software and analysis is
carried out in ANSYS software. The results have shown polymeric-based composite material
meets the requirements of manufacturer’s specification and can be replaced with present metallic
pedal. Weight reduction of 66.7% is achieved by using composite material.
Index Terms—Brake pedal, SUVs car (Sport utility vehicles), CATIA, Erogonomics, Composite
Cite: K K Dhande*, N I Jamadar and Sandeep Ghatge, "Design and Analysis of Composite Brake Pedal: An Ergonomic Approach," International Journal of Mechanical Engineering and Robotics Research, Vol. 3, No. 3, pp. 474-482, July 2014.
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