Design and analysis of vehicle parking brake lever mechanism using topology optimization technique

In recent decades, automotive manufacturers have focused on new technologies to reduce fuel consumption and increase energy efficiency in automobiles. In the context of engineering studies related to the reduction of energy consumption, the decrease in carbon emissions, environmental protection, and climate change, the concept of optimization holds a significant place for sustainability. The components are optimized using structural optimization techniques to achieve the best size, shape and topology in the design. Topology optimization is utilized to reduce the weight of the basic components of vehicles by optimizing the material distribution. The aim of this study is to reduce the weight of a vehicle component without compromising its mechanical properties by using the topology optimization method. Two different parking brake mechanisms (Model 1 and Model 2) were selected as vehicle elements. The braking system has an important role in active and passive vehicle safety systems. Static structural analysis and topology optimization were applied to the main components of the parking brake (lever, gear and trigger). After topology optimization, static structural analyses were repeated for the final geometry under the same conditions (material, load and support points) for verification purposes. In the static analyses, 50, 100, 150, 200, 250, 300, 350, 400 N were applied for the parking brake lever and 100 N were applied for the brake cable connection. A force of 100 N was applied to the gear and trigger elements. Analyses were conducted using AISI 1000, AISI 1020, AISI 4340 and S235 materials. As a response constraint for topology optimization, weight was chosen. The material removal rates were determined as 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, and 95%. The weights of the components before and after topology optimization were compared. The weight reduction for the model 1 parking brake lever and gear is 18.48%, and 34.86%, respectively. The weight reduction for the model 2 parking brake lever, gear and trigger is 13.85%, 21.54%, and 17.66%, respectively. The results of the analysis show that the most appropriate material for the parking brake lever, gear and trigger design is AISI 4340.