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In terms of external loads, we simply have the a 2000 311 N force applied normal to the pedal contact area (2000 N because this is number represents the required force a brake pedal must be designed for in FSAE competition regulations), force of an average person pushing the brakes, about 70 lbf) as well as the gravitational force acting at the center of gravity (as the pedal is being actively pulled down since the top part is essentially floating in air).

  • Disclaimer: In an actually utilized part, I would use a higher load case (preferably 2000 N because that is FSAE regulation) in order to already add in a factor-of-safety to our part and ensure that any extenuating circumstance is accounted for. For this simulation, I chose the smaller number to A) get this example to run quicker but B) showcase how drastic the results of Topology Optimization can be. TL;DR the 311 N is a good benchmark number for everyday use and no crazy circumstance, increase this number to account for those



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Ergo Idea dump (big grin):

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