In recent years, with the continuous breakthrough of additive manufacturing technology, 3D printing technology has been used more and more in the field of industrial manufacturing for component development and testing. Some time ago, Siemens implemented topology optimization for racing accelerator pedals.
Additively manufactured accelerator pedal parts
The performance of the racing accelerator pedal designed and printed through lightweight topology optimization is improved, which improves the overall performance of the racing car; the impact on the environment is reduced through digital simulation optimization and additive manufacturing technology; cost savings (material cost, personnel cost, warehousing cost) ). The specific optimized performance of this pedal is as follows:
• Combining the original 4 parts into 1 integrated part
• Eliminate sheet metal fabrication processes
• Eliminate the welding process
• Use aluminum instead of steel
• 62 percent lighter
Design ideas
First, topology optimization - combining multiple parts into a single model. Combining four parts into one, eliminating the sheet metal fabrication process previously used for all four components and welding procedures, saves assembly labor costs, product complexity, and inventory costs.
Secondly, lightweight design - from the original steel material to aluminum material. On the premise of meeting the mechanical properties of the parts and the needs of the whole vehicle, the counterweight is reduced.
The three iterations of the accelerator in varying states of optimization
The case study produced three different models which were then optimized by Solid Edge sales partner ISAP as examples of generative design. One model shows the initial stage of an AM part; this weighs almost the same as the initial sheet metal part. The second version shows a part that has still a high safety factor and is partially optimized for topology. It weighs 373 g, a reduction in weight of around 14 percent . The third version is fully optimized and weighs only 164 g, a reduction in weight of 62 percent , yet is still a durable solution for the racing car accelerator pedal.