Indian Institute of Technology, Jodhpur

Analysis of Brake Pedal of an All TerrainVehicle

A Design of Machine Element Course Project report under the supervision of

Dr. Barun Pratiher

Mechanical engineering
IIT JODHPUR

Submitted by:
Bhaskar Vijay (B16ME005)
Hemant Kumar (B16ME012)
Sachin Beejawat (B16ME028)
Material Selection-
Brake Pedal Assembly is one of the roughly used assemblies of any vehicle. Also,
when a sudden stop is required often, the brake pedal is pressed many times. Due
to which along with good ultimate tensile strength good fatigue strength is also
necessary.
Also, no one wants to have heavy brake pedal assembly as it leads to wastage of
material, less comfort to drive and unwanted weight to the system.
We started by looking at common materials used for this which are aluminium,
polymer-based composite, Stainless Steel and Mild Steel. Polymer-based
composite is very expensive and fatigue strength of aluminium is very low. So
we left with stainless steel. Fatigue Strength of Fe250 MS Steel and AISI 301 is
almost same and also there is not much difference between ultimate tensile
strength and with easy availability and low cost, we finally go with taking Mild
Steel for both Brake Pedal and Brake Pedal Assembly.

Bolts and Nuts specification-

According to ASME (American Society of Mechanical Engineers), definition the

specification of M8 (Metric unit 8) and M10 (Metric unit 10) is given below and materials
of a bolt, is made from alloy steel is not coated and has a dull black finish. As the bolts
are strong, nuts made from this material are brittle at the same time. Brass is an alloy
of Copper and Zinc.
Theories of Failure-

“Distortion-Energy Theory OR The von Mises Theory “

“Distortion energy theory states that failure by yielding under a combination of

stresses occurs when the energy of distortion equals or exceeds the energy of
distortion in the tensile test when the yield strength is reached. It has been
observed that a solid under hydro-static, external pressure (e.g. volume element
subjected to three equal normal stresses) can withstand very large stresses.
Distortion-Energy Theory OR The von Mises - Hanky Theory It has been
observed that a solid under hydro-static, external pressure (e.g. volume element
subjected to three equal normal stresses) can withstand very large stresses.
Since it was recognized that engineering materials could withstand enormous
amounts of hydro-static pressures without damage, it was postulated that a
given material has a definitely limited capacity to absorb the energy of distortion
and that any attempt to subject the material to greater amounts of distortion
energy results in yielding failure.

According to theory failure criteria is -

S = [σ + σ + σ – σ σ - σ σ - σ σ ]
y 1
2
2
2
3
2
1 2 2 3 3 1
1/2

For two-dimensional stress state (σ2 = 0), the equations reduce to

S = [σ + σ - σ σ ]
y 1
2
3
2
3 1
1/2
Loading Conditions-
Stress and Deflection Analysis
Stress and Deflection Analysis
Stress and Deflection Analysis of Brake foot-
Physical Dimensions and Hand
Calculations for finding Brake Pedal Ratio-
Finite Element Analysis for Stress-Strain for verification-

We use state of the art software package ANSYS for performing the above-mentioned
analysis using Von-Mises Stress theory in ANSYS. Also, Forces on Brake Pedal Clamp
Assembly have also been shown it will also experience significant amount of force from the
pedal.

Fig. : Brake Pedal(left) and Brake Assembly (right) analysis

Solidworks Modeling-