Structural Optimization of the Brake Pedal using Artificial Intelligence

Year 2023, Volume: 7 Issue: 3, 187 - 195, 30.09.2023

Özlem Akçay

https://doi.org/10.30939/ijastech..1330096

Cited By: 4

Abstract

In this study, weight reduction was performed on the brake pedal, which is one of the most important parts of the braking system, by using topology and shape optimi-zation, one of the structural optimization methods, respectively. The aim of the study is to develop an optimal design that reduces vehicle weight by finding the optimal material distribution for the brake pedal. The weight reduction process was carried out in two steps. In the first step, static analyses were performed on the starting brake pedal model. Later, topology optimization was performed for weight reduction pur-poses. After the topology optimization, new brake pedal design was created and weight reduction was performed. In the second step, shape optimization was per-formed using a genetic algorithm to obtain the optimal dimensions of the brake pedal. According to the optimization results, the weight of the design was reduced from 437 grams (g) to 326 grams (g) by topology optimization in the first step. So the new de-sign is 25.4% lighter compared to the first design. Later, as a result of shape optimiza-tion performed using a genetic algorithm, the weight was reduced from 326 g to 298 g and the optimal dimensions of the brake pedal were determined. Thus, with shape op-timization, a lighter brake pedal design of about 8.5% was achieved compared to to-pology optimization. As a result, the weight has been reduced from 437 g to 298 g, and the weight of the ideal brake pedal model is 31.8% lighter compared to the main model.

Keywords

Structural analysis, Topology optimization, Shape optimization, Genetic algorithm, Brake pedal.

References

• [1] Mete E, Başak H. Topoloji optimizasyonu kullanilarak rot başi tasarimi, analizi ve doğrulanmasi. J Polytech. 2023;0900:0–1.
• [2] Kip M, Goren A. Topology optimization study for rear swing arm of a lightweight solar-powered vehicle. J Sci Technol Eng Res. 2022;3:42–9.
• [3] Xie YM, Steven GP. Optimal design of multiple load case structures using an evolutionary procedure. C. 11, Engineering Computations. 1994.
• [4] Woldseth R V., Aage N, Bærentzen JA, Sigmund O. On the use of artificial neural networks in topology optimisation [Internet]. C. 65, Structural and Multidisciplinary Optimization. Springer Berlin Heidelberg; 2022. 1–36 s. Available at: https://doi.org/10.1007/s00158-022-03347-1
• [5] Liu X, Featherston CA, Kennedy D. Two-level layup optimization of composite laminate using lamination parameters. Compos Struct. 01 Mart 2019;211:337–50.
• [6] Özarpa C, Botsali H, Kinaci BF. Raylı sistemlerde kullanilan cer kancasinin topoloji optimizasyonuna uygunluğunun değerlendirilmesi. Demiryolu Mühendisliği. 2022;(15):1–12.
• [7] Andreassen E, Clausen A, Schevenels M, Lazarov BS, Sigmund O. Efficient topology optimization in MATLAB using 88 lines of code. Struct Multidiscip Optim. 2011;43(1):1–16.
• [8] Lin CC, Lee YJ. Stacking sequence optimization of laminated composite structures using genetic algorithm with local improvement. Compos Struct. 2004;63(3–4):339–45.
• [9] Stromberg LL, Beghini A, Baker WF, Paulino GH. Topology optimization for braced frames: Combining continuum and beam/column elements. Eng Struct. Nisan 2012;37:106–24.
• [10] Sciences E, Kara F, Arda C, Engineering M, Sciences E. Topology Optimization Of The Load-Carrying Element. 2021;22(2):57–64.
• [11] Izgi B, Eryildiz M, Altan M. Topological optimization of brake pedal for metal additive manufacturing: A case study optimization of brake pedal for metal additive manufacturing: a case study. Int J Adv Des Manuf Technol. 2021;14(2):123–30.
• [12] Kulangara AJ, Rao CSP, Cherian J. Topology optimization of lattice structure on a brake pedal. Içinde: Materials Today: Proceedings. Elsevier Ltd; 2021. s. 5334–7.
• [13] Sargini MIM, Masood SH, Palanisamy S, Jayamani E, Kapoor A. Additive manufacturing of an automotive brake pedal by metal fused deposition modelling. Içinde: Materials Today: Proceedings. Elsevier Ltd; 2021. s. 4601–5.
• [14] Yildiz AR. A new hybrid particle swarm optimization approach for structural design optimization in the automotive industry. Proc Inst Mech Eng Part D J Automob Eng. 2012;226(10):1340–51.
• [15] Albak Eİ. optimum design of brake pedal using topology optimization method intended for weight reduction on the Formula SAE Car. Uluslararası Muhendis Arastirma ve Gelistirme Derg. 31 Ocak 2019;328–34.
• [16] Mortazavi A, Toğan V, Daloğlu A, Nuhoğlu A. Comparison of two metaheuristic algorithms on sizing and topology optimization of trusses and mathematical functions. J Sci [Internet]. 2018;31(2):416–35. Available at: http://dergipark.gov.tr/gujs
• [17] Koçak MR, Korkut İ. Application of topology optimization method for unmanned aerial vehicle nose landing gear fork. J Polytech. 2022;0900:0–3.
• [18] Selmi̇ M, Yeşim Ilerisoy Z. A comparative study of different grasshopper plugins for topology optimization in architectural design. J Sci [Internet]. 2022;3(10):323–34. Available at: http://dergipark.gov.tr/gu.jsb
• [19] Zhu B, Zhang X, Zhang H, Liang J, Zang H, Li H, vd. Design of compliant mechanisms using continuum topology optimization: A review. C. 143, Mechanism and Machine Theory. Elsevier Ltd; 2020.
• [20] Aage N, Andreassen E, Lazarov BS. Topology optimization using PETSc: An easy-to-use, fully parallel, open source topology optimization framework. Struct Multidiscip Optim. 2015;51(3):565–72.
• [21] Van Dijk NP, Maute K, Langelaar M, Van Keulen F. Level-set methods for structural topology optimization: A review. Struct Multidiscip Optim. 2013;48(3):437–72.
• [22] Cavazzuti M, Baldini A, Bertocchi E, Costi D, Torricelli E, Moruzzi P. High performance automotive chassis design: A topology optimization based approach. Struct Multidiscip Optim. Temmuz 2011;44(1):45–56.
• [23] Fan W, Xu Z, Zhang Z. A PID-optimality criteria method for structural topology optimization. Optim Eng [Internet]. 2023; Available at: https://doi.org/10.1007/s11081-023-09810-2
• [24] Guo X, Cheng GD. S-relaxed approach in structural topology optimization. Struct Optim. 1997;(1972):258–66.
• [25] Yang RJ, Chahande AI. Automotive applications of topology optimization. C. 9, Structural Optimization. Springer-Verlag; 1995.
• [26] Zhang Z, Zhang C, Qiao Y, Zhou Y, Wang S. Design and mass optimization of numerical models for composite wind turbine blades. J Mar Sci Eng. 01 Ocak 2023;11(1).
• [27] Deaton JD, Grandhi R V. A survey of structural and multidisciplinary continuum topology optimization: Post 2000. Struct Multidiscip Optim. 2014;49(1):1–38.
• [28] Song X, Chen D, Qu B. Topology optimization of robotic arm for gas drainage pipeline installation. J Phys Conf Ser. 2022;2383(1).
• [29] Chen L, Zhang H, Wang W, Zhang Q. Topology Optimization Based on SA-BESO. Appl Sci. 2023;13(7).
• [30] Zhu J, Zhou H, Wang C, Zhou L, Yuan S, Zhang W. A review of topology optimization for additive manufacturing: Status and challenges. C. 34, Chinese Journal of Aeronautics. Chinese Journal of Aeronautics; 2021. s. 91–110.
• [31] Mauersberger M, Hauffe A, Hähnel F, Dexl F, Markmiller JFC. Topology optimization of a benchmark artifact with target stress states using evolutionary algorithms. Eng Comput [Internet]. 2023;(0123456789). Available at: https://doi.org/10.1007/s00366-023-01860-5
• [32] Wang G, Wang D, Liu A, Dbouk T, Peng X, Ali A. Design and performance enhancement of thermal-fluid system based on topology optimization. Appl Math Model. 01 Nisan 2023;116:168–86.
• [33] Kopar, M. and Yildiz, A. Composite disc optimization using the hunger games search optimization algorithm. Materials Testing. 2023:65(8); 1222-1229.
• [34] Millo F, Arya P, Mallamo F. Optimization of automotive diesel engine calibration using genetic algorithm techniques. Energy, 2018:158; 807-819.
• [35] Delissen A, van Keulen F, Langelaar M. Integrated topology and controller optimization using the Nyquist curve. Struct Multidiscip Optim [Internet]. 2023;66(4):1–25. Available at: https://doi.org/10.1007/s00158-023-03515-x
• [36] Sigmund O. On the usefulness of non-gradient approaches in topology optimization. Struct Multidiscip Optim. 2011;43(5):589–96.
• [37] An H, Youn BD, Kim HS. Reliability-based Design Optimization of Laminated Composite Structures under Delamination and Material Property Uncertainties. Int J Mech Sci. 01 Eylül 2021;205.
• [38] Wei R, Pan G, Jiang J, Shen K, Lyu D. An efficient approach for stacking sequence optimization of symmetrical laminated composite cylindrical shells based on a genetic algorithm. Thin-Walled Struct. 01 Eylül 2019;142:160–70.
• [39] Soremekun G, G Urdal Z, Haftka RT, Watson LT. Composite laminate design optimization by genetic algorithm with generalized elitist selection [Internet]. Available at: www.elsevier.com/locate/compstruc
• [40] Mathias JD, Balandraud X, Grediac M. Applying a genetic algorithm to the optimization of composite patches. Comput Struct. Mayıs 2006;84(12):823–34.
• [41] Fan HT, Wang H, Chen XH. An optimization method for composite structures with ply-drops. Compos Struct. 01 Şubat 2016;136:650–61.
• [42] Almeida JHS, Ribeiro ML, Tita V, Amico SC. Stacking sequence optimization in composite tubes under internal pressure based on genetic algorithm accounting for progressive damage. Compos Struct. 15 Ekim 2017;178:20–6.
• [43] Scappaticci L, Bartolini N, Guglielmino E, Risitano G. Structural optimization of a motorcycle chassis by pattern search algorithm. Eng Optim [Internet]. 2017;49(8):1373–87. Available at: http://dx.doi.org/0305215X.2016.1256393
• [44] Wang L, Bayer SE. N91-4o50 Genetic Algorithms.
• [45] Kumar M, Husain M, Upreti N, Gupta D. Genetic Algorithm: Review and Application. SSRN Electron J. 2020;2(2):451–4.