Application of finite element analysis in the development of the pedal assembly of the Formula Student racing car

Abstract

The study is focused on presenting an assessment of additive manufacturing usage in modern technological processes, including the manufacturing of parts of the racing car participating in Formula Student project. It shows the necessity of simulating physical processes during the design stage using the finite element analysis. The issues of calculating the strength of pedals of various functional purposes are considered. The boundary conditions imposed on the accelerator pedal are presented. It was found that loads applied with an offset to the edge of the support platform cause higher stresses in the item. The distribution patterns of the safety factor of an accelerator pedal created by additive method from materials: acrylonitrile butadiene styrene, polyamide Nylon 6/6 and polyamide Nylon 6/6 reinforced with fiberglass are presented. The results of modeling the rigidity of the pedal structure and the maximum stresses arising in it under load are indicated. The results of simulation of the prefabricated structure of the accelerator pedal with an aluminum alloy lever with a pedal plate obtained by additive manufacturing are shown.