7/27/2019 Custom Design and Analysis of Clutch Pedal
1/13
650:342
Analysis And Design of Custom
Hydraulic Clutch Pedal
Zachariah John
Henry Helfman
Bernadette Bautista
7/27/2019 Custom Design and Analysis of Clutch Pedal
2/13
Previous Pedal Design
Uses rod and crank system
Requires adjustment to
compensate clutch wear
Has 6 major high wear
surfaces
Mechanical geometry
(pivot points) limits
applications
7/27/2019 Custom Design and Analysis of Clutch Pedal
3/13
Bell Crank
Cable Clutch System
Non-Hydraulic
Clutch Linkage
Systems
7/27/2019 Custom Design and Analysis of Clutch Pedal
4/13
Hydraulic Clutch System Advantages
1. Easy to mount master
cylinder on flat surface
behind pedal (firewall)
2. Few wear items which
have much lower wear
than other clutch
linkage systems
3. Piston/Cylinderassemblies
automatically
compensate for clutch
surface wear and need
no adjustment
7/27/2019 Custom Design and Analysis of Clutch Pedal
5/13
Improved Design Goals
1. Make a system which allows
installation of hydraulic clutch
pedal when standard parts are
unavailable
2. Use mostly production or
aftermarket parts and keep custom
manufactured parts to a minimum
to be cost effective and practical
3. Use simple system that can be
implemented to any vehicles
firewall section (space permitting)
7/27/2019 Custom Design and Analysis of Clutch Pedal
6/13
Model Information
The improved pedal is a modified bell
crank unit retrofitted to operate a
Hydraulic Master Cylinder.
An actuation arm which joins the pedal
to the master cylinder rod is welded to
the original pedal.
The pedalhas a weight of 1.869 lb
(4.8359E-03 lbm).
Galvanized Annealed Steel is the
material used in the pedal.
7/27/2019 Custom Design and Analysis of Clutch Pedal
7/13
Material Properties for
Galvanized Annealed Steel
Modulus of Elasticity[psi] 2.7993E+07
Density [lbm/in^3] 7.5148E-04
Poisson's Ratio 0.2900
Thermal ExpansionCoefficient [ 1/degF ] 9.8889E-06
7/27/2019 Custom Design and Analysis of Clutch Pedal
8/13
Constrained and
loaded with 20 lb
applied load to lower
base pedal surface
Analyzed with Ansys
FEA Loads & Constraints
7/27/2019 Custom Design and Analysis of Clutch Pedal
9/13
Analysis Specifications
Applied Loads:
Type Entity X Y
Force [ lb ] Area 91.56 8.010 Force [ lb ] Area -14.14 -14.14
Reaction Forces [ lb ]:
X Y Z
-76.867 -22.103 -4.12794E-04
Total Moment [ lb-in ]:
X Y Z
7.4646 -85.318 98.502
7/27/2019 Custom Design and Analysis of Clutch Pedal
10/13
Equivalent Stress, Maximum
Principal Stress and Critical Point
7/27/2019 Custom Design and Analysis of Clutch Pedal
11/13
Fatigue Test
The Critical Stress (SC) on the clutch pedalis24.750 ksi.
108
Cycle Strength (endurance limit):Sn =Sn' * CL * CG * CS Sn' = 0.5*SU
= 25.48125 ksi. SU = 151 ksi
CL = 1
CG = 0.75
CS = 0.4
Since SC < Sn fatigue life is infinite.
7/27/2019 Custom Design and Analysis of Clutch Pedal
12/13
Corrosion & Wear Analysis
Pedal surfaces are painted
Every frictional surface is lightly greased and
insulated with a plastic bushing so anodiccorrosion of the material is irrelevant.
Rod is in contact with the pedal, which gives wayto adhesive wear.
Wear: W= KHFS K=10-3
= 5.0744*10-8 in.3 H= 452.832*103 psi.
= 8.3154*10-4 mm.3 F = 91.9134 lb.
S = 0.25 in.
7/27/2019 Custom Design and Analysis of Clutch Pedal
13/13
Disposal
Pedal assembly will
most likely be
salvaged at end ofvehicles useful life or
recycled with the rest
of the vehicle
Top Related