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650:342 Analysis And Design of Custom Hydraulic Clutch Pedal

650:342 Analysis And Design of Custom Hydraulic Clutch Pedal. Zachariah John Henry Helfman Bernadette Bautista. Previous Pedal Design. • Uses rod and crank system • Requires adjustment to compensate clutch wear • Has 6 major high wear surfaces

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650:342 Analysis And Design of Custom Hydraulic Clutch Pedal

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  1. 650:342Analysis And Design of Custom Hydraulic Clutch Pedal Zachariah John Henry Helfman Bernadette Bautista

  2. 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

  3. Non-Hydraulic Clutch Linkage Systems Bell Crank Cable Clutch System

  4. Hydraulic Clutch System Advantages • Easy to mount master cylinder on flat surface behind pedal (firewall) • Few wear items which have much lower wear than other clutch linkage systems • Piston/Cylinder assemblies automatically compensate for clutch surface wear and need no adjustment

  5. 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 vehicle’s firewall section (space permitting)

  6. 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. 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 Expansion Coefficient [ 1/degF ] 9.8889E-06

  8. FEA Loads & Constraints • Constrained and loaded with 20 lb applied load to lower base pedal surface • Analyzed with Ansys

  9. 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

  10. Equivalent Stress, Maximum Principal Stress and Critical Point

  11. Fatigue Test • The Critical Stress (SC) on the clutch pedal is 24.750 ksi. • 108 Cycle Strength (endurance limit): Sn =Sn' * CL * CG * CSSn' = 0.5*SU = 25.48125 ksi. SU = 151 ksi CL = 1 CG = 0.75 CS = 0.4 Since SC < Sn fatigue life is infinite.

  12. Corrosion & Wear Analysis • Pedal surfaces are painted • Every frictional surface is lightly greased and insulated with a plastic bushing so anodic corrosion of the material is irrelevant. • Rod is in contact with the pedal, which gives way to adhesive wear. • Wear: W= KHFS 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.

  13. Disposal • Pedal assembly will most likely be salvaged at end of vehicle’s useful life or recycled with the rest of the vehicle

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