Multidisciplinary Approach to Aluminum Parking Brake Lever Development: Enhancing Performance and Sustainability through Structural Optimization

In response to increasing environmental awareness and the automotive industry's push for sustainability, the development of lightweight and robust components has become a key area of focus. This paper presents a multidisciplinary approach to the design and optimization of an aluminum parking brake lever, leveraging advanced structural optimization techniques to enhance performance while meeting stringent environmental standards. Traditional manufacturing processes for automotive components, such as stamping, often rely on steel due to its strength and ease of processing. However, the high density of steel can significantly impact the overall weight of the vehicle, leading to increased fuel consumption and emissions. In contrast, aluminum’s superior strength-to-weight ratio offers a promising alternative. This study employs Finite Element Analysis (FEA) to model the initial stress history of the lever, followed by the application of structural optimization tools to refine its geometry for weight reduction and performance enhancement. The optimization process focuses on maintaining or improving the structural integrity of the component while achieving significant reductions in weight. By integrating Computer-Aided Design (CAD) and Computer-Aided Engineering (CAE) tools, the study demonstrates how a multidisciplinary approach can lead to innovative solutions that align with both performance requirements and sustainability goals. The results highlight that the use of aluminum, in conjunction with optimization methods, leads to a considerable weight reduction compared to the traditional steel design, while maintaining the necessary robustness for automotive applications. The study not only provides insights into material substitution but also emphasizes the role of structural optimization in modern automotive engineering, contributing to more sustainable manufacturing practices.