Finite element analysis of automotive arm brake pedal for rapid manufacturing

Abstract

Current automotive arm brake pedal uses conventional manufacturing method such as metal press and CO2 welding processes, which are known to be heavy, costly and demand higher quality control. This paper will discuss how finite element analysis can be applied to optimise the design of a brake pedal for Rapid Manufacturing application based on current additive manufacturing process to produce automotive brake pedals with reduced material weight. The performance of the new design is compared with the current design of arm brake pedal to realise the potential of rapid manufacturing to save time and cost in automotive parts.