Topology Optimization and Experimental Validation of a Baja Competition Brake Pedal Design

The automotive industry continually seeks innovative methods to reduce vehicle weight, enhance efficiency, and maintain structural integrity. This study presents a detailed framework that combines topology optimization (TO) and experimental validation, applied specifically to the design of a brake pedal for a Baja competition vehicle. The research involves a multi-step process, starting with finite element modeling, followed by TO using ANSYS Workbench to optimize the pedal's material distribution for weight reduction. Post-processing in Siemens NX is then performed to incorporate manufacturing constraints, ensuring the design is suitable for water jet cutting. The optimized brake pedal, constructed from 7075-T6 aluminum, weighs 42.6 g and demonstrates stress levels well below the yield strength of the material. Dimensions were determined based on the available space within the vehicle to ensure that the brake pedal would not interfere with any vehicle structure and would not impede the driver during operation. These considerations ensured that the pedal’s design maximized comfort and safety for the driver. Experimental validation is conducted through force and strain measurements, resulting in a 3.5% discrepancy between simulated and experimental stress values. Over 50 hours of track testing, including extensive on-road competition use, confirms the robustness and practical viability of the optimized design. This work underscores the potential of TO as a powerful tool for lightweight component design, demonstrating its integration with real-world testing and the ability to enhance the manufacturability of critical automotive components. The framework presented here not only validates the design process for brake pedals but also offers a versatile approach applicable to other vehicle components, contributing to the broader goal of optimizing automotive performance through lightweight designs.