I

i ABSTRACT

Currently, the car will continue to be used for passenger cars so as to improve fuel efficiency
and harmful substances. It is important to develop and maintain the vehicle with the proper
weight to make the performance of the vehicle better. In this region, according to firm's
standards and regulations, the manufacturer will continue to work on characteristics, designs
and materials, different types to develop new components that have the same safety
specifications, but are not expensive, and are lighter in weight than existing products. This
study will show the capability of analysis, a new vehicle design, and the brake pedal. To
reduce the weight of alternative plasma welding designs, two studies in part, non-monoblock,
gas during arc welding of the brake pedal shift lever. Estimated maintenance bill conditions,
both existing and new pedals, linear static stress analysis is done by the method for the last
elements. There are certain critical areas where stress concentration occurs. To assess the
fatigue strength of the brake pedal, use the stress-resource method. Based on the results of the
analysis, design, revolutionary solutions were prepared, which were adopted to extend the
service life of the new brake pedal. Calculated analysis of the fatigue life of pedals approved
for use on specially designed testing rigs.
 Literature Review

Automotive Product Development through Value Engineering Strategies and Value Analysis
(VAVE)
INTRODUCTION
Value Engineering is a consistent and targeted method of evaluating the value or usefulness
of a product to target consumers. It aims at the desired Product functions, process, service and
system in which by maintaining performance, aesthetics, high cost of life cycle, quality
reliability, strict security.

CONCEPT
Value Engineering identifies product performance parameters where improvement is
expected. VE uses the team work principle as in the product life cycle owners of various
stacks, the functions include product costs, cost effectiveness is improved when all
stakeholders use their talent to achieve the same goal. Value Engineering initially aims to
identify product functions for basic function, secondary work, one-time work, full-time work.

METHODOLOGY
Product cost is becoming an important factor of success within industry. For applying VE in
any product/project systematic application of techniques is very important. It is kind of
organized plan of action for VE deployment including implementation of recommended
changes in the design.
1. Orientation phase,
2. Information phase,
3. Function phase,
4. Creativity phase,
5. Evaluation phase,
6. Recommendation phase,
7. Presentation Phase,
8. Implementation phase
1. Orientation phase:
The purpose of this section is to understand the area in which VE will be used that will lead
to profitability, improve product performance and increase customer satisfaction. Before
starting any of the VE projects below, two things should be considered:
Complex or expensive materials provide a wide range of VE study. Power Index = (Expected
Research Expectations / Expected Study Expenditure) x Opportunities for submission.
Where, expected research savings = Product costs before VE - Expected product costs after
VE (Rs.) Expected tuition costs = Study costs for VE + Shipping costs (in Rs.) Opportunities
for installments between 0 - 100% are represented by decimal. 0% represents no shipping
opportunities, 100% (1.0) represents guaranteed shipping opportunities. Where VE research
has a high cost-saving index it should be considered first in VE efforts. Example: Suppose we
would like to introduce a plastic cooling tank instead of a metal cooling tank.
Assumption:
1. Cost of existing metallic coolant tank is Rs 1200.
2. Cost of plastic coolant tank is Rs 800.
3. Expected required volume of plastic coolant tank 300 Nos.
4. Expected cost of tooling development Rs 10. Lacs
5. Expected VE study cost Rs 40,000 6. Expected deployment cost Rs 2. Lacs.
2. Information phase:
The purpose of this phase is to gather enough information about a project that will be studied
for consideration by VE. This phase consists of identifying the strength of a VE project by
studying the cost of the life cycle and wherever a low product value is taken as the target
price requires an explanation and collection of detailed information and product data by
identifying all costs and analyzing competing data for the same product portfolio.
3. Function phase:
The objective of this stage is to appropriately examine and portray the different elements of
the item alongside expenses and relative worth. The client buys the item since it gives
required capacity at an expense which client is prepared to pay on the off chance that item
neglects to play out its proposed capacities, such an item is of no utilization to the client in
such case esteem designing can't work on its worth.
5. Evaluation Phase:
In this stage diverse VE proposition which have been read for item are talked about top to
bottom utilizing Decision network, Paired Comparison Matrix
6. Recommendation Phase:
Objective of this stage is to gather extra information to completely examination the best VE
proposition.
7. Presentation Phase:
The motivation behind this part is to convey the suggested VE proposition before a dynamic
panel so that the best VE proposition is booked for determination. 8. Execution Phase: The
motivation behind this part is to guarantee that the suggested VE proposition is carried out
methodicallly so investment funds can start or the improvement of any task project is viewed
as genuine.

COST REDUCTION USING VALUE ANALYSIS FOR AUTO RICKSHAW

STEERING BAR

INTRODUCTION
Numerous decreases in item costs in the business happen during the presentation of another
item. Nonetheless, in certain organizations, the charge can be put forth that attempts to
diminish item expenses can be aimed at items that have effectively been created. These
organizations manage a bunch of business conditions that regularly forestall all out cost
decrease of the item. The most significant issue confronting the area today is the issue of
increasing expenses. Over the past decade, the two major problems facing the sector are: -

 The high cost of equipment

 The achieving of suitable reliability

I. IMPLEMENTATION OF VALUE ANALYSIS JOB PLAN

1 Phase 1-
General Section This segment portrays the overall rules that are followed for any remaining
classifications. The diverse work of the scientist was taken as a kind of perspective and the
organization official was considered during the choice of the undertaking, which was the
primary errand at this stage. The undertaking is considered as far as the accompanying rules.
 It must have at least 3 different subassemblies
 It must be in current usage
 It must have 8 to 16 components or actions
 No major changes in the item should be in process
 It should be something on which changes can be made after the process of
recommendations  Its purpose or functions should be properly definable and understandable
Auto rickshaw steering bar was taken for study which satisfied the above mentioned
considerations.

2 Phase 2-
Data Section In this segment, all data and business related data was gathered. All standard
area rules are utilized widely in the data segment. 1) Protect the realities The initial step was
to get all the applicable data about the organization like its different items, units, number of
representatives, association graph and so forth The processing plant has 50 workers and the
organization is engaged with the assembling of different parts of Bajaj, Hero Honda, Vespa,
Axel, Ape and Suzuki. In the assembling of different components the organization is engaged
with different projects like Boring, Turning, Chamfering, Tempering, Grinding, Radius,
Checking (quality), Packing (with rust evidence confirmation). Every one of these cycles is
utilized for an assortment of get together exercises. Each has its own expense and a specific
measure of disposed of things. 2) Details of the Production Procedure for the Selected
Meeting. The creation interaction of Bajaj auto carts auto cart gathering can be perceived as
follows. The gathering comprises of five things to be specific 1) Lower cup 2) Lower cone 3)
Upper cup 4) Upper nut check 5) Unusual check nut The creation cycle for every one of the
above things incorporates a progression of stages that incorporate various undertakings to be
acted in each stage. The costs engaged with every class are additionally expressed in an
outline of every segment. Table 1 Component/measure and their complete expense
Phase 3
3 Defining the Function
The functions of all the parts of the Bajaj auto rickshaw steering bar assembly were defined.
Functions were classified as primary and secondary at the part level. To define the function
closely, certain basic established guidelines and rules were used.

Phase 4
Construction Phase So far the product has been considered in its original form. Nothing has
been done on the part of improving quality or reducing costs according to customer
requirements and operational requirements. On the basis of the VEJP, jobs are identified as
low-cost jobs. This has now been considered in the creative phase of improvement. a)
Linking to an existing solution: - one should focus on activities and not on construction or
existing solutions. b) Complete or complete self-confidence: - one must have a firm belief in
something new and better can be developed, as the existing structure is useless.
Phase 5
Evaluation Phase The purpose of the evaluation phase of the engineering work program is to
carefully evaluate the results produced in the intelligence phase by reviewing various
alternatives to select the best value proposition. The ideas listed are discussed in terms of
their effectiveness and cost effectiveness. A competent request is made to prevent and
eliminate unnecessary development costs, remembering or ensuring that the product is not
sold at all or reduced e.g. This section uses the following strategies. Evaluate ideas Establish
costs for all ideas.

STATIC STRUCTURAL ANALYSIS AND OPTIMIZATION OF BRAKE

PEDAL

Miss. ASHWINI N.GAWANDE1, Prof.G.E.KONDHALKAR2, Prof. ASHISH R.PAWAR3

INTRODUCTION
1.1 Background In recent year
Hardware rivals each other for existing and new business sectors. Brake pedals are utilized by
the driver of the vehicle to apply the brakes. The slowing mechanism in the vehicle is a shut
pressure driven framework and depends on close resilience between the brake shoes and the
drums or brake lines and rotors. It is quite possibly the main vehicle programs. It has certain
fundamental jobs, it needs to hinder the moving vehicle, it needs to keep the vehicle standing
when it is halted, It needs to stop the vehicle.
The TATA STORME Brake pedal is utilized as a component of the study.The CAD brake
pedal is created in 3D displaying programming CATIA V5. In the car business, weight
reduction turns into a significant issue. To decrease gear, use Topology is utilized. Further
developing it diminishes the weight and cost of the item. In the car business, it is obligatory
to search for inexpensively lightweight things that ought to be promptly accessible. At
present, brake pedals are made of steel however gas pedal pedals and grasp pedals are utilized
effectively in car vehicles. This examination centers around the factors of the idea of the plan
of idea brakes.

INTRODUCTION

VALUE ANALYSIS

• Value analysis is one of the major ways to reduce costs and control costs. It is a guided
method that ensures the required low cost functions without compromising on quality,
reliability, performance and appearance.
• It is a creative way to eliminate unnecessary costs that do not add to the quality or
appearance of the product. Systematic use of techniques to identify the functions of a product
or object and to provide the desired function at a very low cost.
• Therefore, it can be defined as, 'Value analysis is a systematic way of identifying
unnecessary costs associated with any product, asset, component, component, system or
service by analyzing work and eliminating it effectively without compromising quality
performance or performance capacity. '
• In the field of value analysis, value refers to the economic value, which in itself can be
divided into four categories such as cost value, exchange rate, consumption value and value.
• “Value Value” is the sum of all the costs incurred in producing a product. ‘Cost cost’,
therefore, is the total cost of raw material, labor costs, cost of tools and heads used to produce
the product.
• “Value Value” is a measure of all the properties, qualities and characteristics of a product
that enable a product to be sold for another product or for money. In a general sense,
‘exchange rate’ refers to the price the consumer will offer in a product, the price depends on
the satisfaction value found in the product.

BRAKE PEDAL

A brake pedal is a pedal that you press with your foot to make the vehicle moderate or stop.
At the point when the driver puts his foot on the brakes, the framework consequently applies
the most extreme pressing factor expected to try not to hit the vehicle before him.
The back brake lights produce an assortment of red lights relying upon the energy level
utilized in the brake structure.

There are different types of brake pedal, Typically, the regular vehicles have four common
brake pad types:

1. Semi-Metallic
With durability and the ability to transfer excellent heat, semi-metallic is the most common
type of brake pad widely used in various vehicles. It is made of steel or wool wire, graphite or
copper, as well as collision variants.

Such a brake pad contains approximately 30% -65% of the metal. It creates a lot of noise,
instills rotors quickly, and performs well at low temperatures.

2. Non-Asbestos Organic

Ropes, high temperature frames, and filling materials are used in the manufacture of this type
of brake pad. Compared to the semi-metallic type, they are softer and produce less noise; but
it quickly deteriorates and creates a lot of dust. These types of brake pipes are sometimes
classified as organic or NAO.

3. Low-Metallic NAO

These mapads brakes are made of 10% -30% steel materials such as steel or copper in
mixing. Although they create a lot of noise and dust, their brakes and heat transfer capacity
are excellent.

4. Clay

You can never find a small amount of metal in this type of brake pad, but it is mainly made of
ceramic fibers, bonding agents, and wireless fillers.
They make less noise, wear less compared to other types of brakes, and form less dust. The
only downside to them is that they have higher prices than other brake pads.

Parts of brake pedal assembly

Stop light switch
Brake light is an electric light that controls the use of brake lights. When the pedal is pressed,
the brake light makes contact, and the brake lights illuminate.

Pedal bracket
Bottom bracket: A system that carries pedals (and cranks) around the perimeter. It contains a
spinning rod attached to the crankset and the bears themselves. There is a place for the
scepter, and for all the cups that go into the frame.

Cushion plate
a rowing plate is a plate placed between a spring plate and a pillow. The spring plate and the
plate plate prevent damage. The Cushion plate is widely used in the automotive industry. The
Cushion plate is made of steel. And the quality of the wood plate should be of the highest
quality.

Pedal pad
It is a rubber pad placed on the piercing surface with a step that connects directly to our foot
to step on the brakes. It also provides sliding features for better grip and brake comfort.
The Automotive Industry keeps on taking a stab at a lightweight vehicle to further develop
eco-friendliness and lessen contamination. Plan vehicles that have the right weight for great
vehicle execution. At the point when the heaviness of the vehicle is diminished, the necessary
main impetus diminishes. As a general rule, for all vehicle weight reduction by 10%, vehicle
use diminishes by 5-7%. The standard engine slowing mechanism works by moving the force
applied by the driver to the brake structure, by water powered brake liquid, to tie to each
wheel. Since, the brake liquid is limitless and can move all the energy utilized in the brake
design to the brakes. The brake disappointment of the vehicles is liable for training the driver
with the foot on the expert chamber of the stopping mechanism in the vehicle during halting
or easing back of the vehicle speed. Pressing factor is needed with brakes that log jam and
stop the vehicle a lot bigger than the pressing factor that drivers can apply with their foot;
regularly multiple times the power of break. techniques help increment slowing down
pressure. In the first place, the brake pedal is extraordinarily planned as an oar to recreate the
force utilized by the driver. Second, a vacuum supporter unit is utilized to help slowing down
by expanding the pressing factor of the water driven circuit. Third, the regions related with
the expert chamber cylinders, which really separate the brake liquid and decide the water
driven augmentation factor. Therefore, the pilot foot power of a couple dozen Newtons turns
into two or three thousand Newtons in the brakes. In flight conditions, a substantial individual
can undoubtedly push with more noteworthy power than 300 N. The essential framework for
brake pedal get together is displayed in. The most widely recognized brake pedals in the car
business are made by pressure made of pre-collected steel pieces of adequate shape and size.
It is notable that the creation of metal pedals with a media development strategy can mess
laughing hysterically. Breaks were found in the basic spaces of the part showing an absence
of delicateness of e-content. In books, there are numerous works that are imprinted in metal
or in some other type of material. Normal parts of coordination are found in the producer's
books, manuals and different assets. In the writing, there is a great deal of work that includes
the plan, the test needed to present a brake that moves from steel to a polymer compound
[4,5,6,9,10,11,12]. Figure 1. Essential plan of the brake gathering (2004 Prius - Preliminary
Release) However, in current applications, strong sheet materials, 8 mm thick, are utilized to
deliver the limiting advance, as displayed in Fig. the new plan we are presenting, the pedal
requires two welding things; each with a distance across of 1.4mm. With current innovation,
the circular segment welding steel framework is utilized for 8mm solidness. At the point
when this equivalent welding framework is utilized for a thickness of 1.4mm material,
different issues emerge like openings in the welding region, insufficient cleaning. In view of
current realities, it is resolved that the plasma welding framework, generally reasonable for
little articles, is utilized. Albeit various sorts of plasma innovation are being tried in various
creation regions, it is the first run through to utilize the plasma welding strategy in pedal
creation.

CONCEPT
 VE identifies product performance parameters where improvement or improvement is
expected. Value Engineering uses the team work principle as in the product life cycle owners
of various stacks, the functions include product costs, cost effectiveness is improved when all
stakeholders use their talent to achieve the same goal. Value Engineering initially aims to
identify product functions for basic function, secondary work, one-time work, full-time work.

MATERIAL SELECTION
Following factors are considered for material selection
1. Strength to weight ratio
2. Moldability
3. Physical and mechanical properties
4. Availability

There is polyamide (nylon) with small glass fibers of various percentages. Long glass fibers
are unsuitable due to fiber terminals and their corners may overlap. Therefore, in
consideration of strength and durability. Short glass fiber is the simplest of all materials, with
very little durability. Nylon with short fiber has a high impact force, which is an important
factor in the construction of brakes. Considering% expansion and other structures nylon with
short strands are selected as step piercing materials.

Ergonomic Considerations
This is the emphasis of the study on the combination of ergonomics and integrated materials
to reduce weight and increase the comfort of drivers. As mentioned, drivers comfort the main
concern in the construction of accessories accessible to the driver. The main purpose of this
study was to understand the relationship between driver perception of comfort and the
characteristics of engineering construction associated with pedal design. It is well-known that
to get this attention, we need to focus on two things

• The need to understand the relationship that exists between the actual response of the
drivers, i.e., what the driver actually does with the position, position and position adjustment,
pattern and magnitude of the movement required to complete the driving task and the driver's
comfort concept, i.e., automatic response. • The need to explore the connection between
pedal design and other relevant engineering attributes (such as input) and actual driver
response. The following is an ergonomic factor that affects the comfort of the driver.
• Head anthropometrics (Legs, leg length, trunk, soft tissues).
• Driver position (Seat position, seat angle).

. Vehicle interior points and dimensions

Conceptual Brake Pedal Lever Arm Profile Design

The conceptual design of the polymeric-based composite brake pedal concentrates on beam
for the design of the brake pedal lever. There are four concepts of beam. The design
parameters proposed by General
 Conceptual Design of Brake Pedal Lever Profile.

The conceptual design of the composite brake made of polymeric is a key phase of the
solution. Different designs are considered. The design concept of a polymeric-based
composite brake pedal focuses on the design block of the brake pedal.
Brake pedal pad concept
 Concept Computer Aided Design (CAD) of Brake Pedal

Computer aided design frameworks started to give a larger number of abilities than
penmanship in electronic composition, the money saving advantage of organizations
changing to CAD became clear. The advantages of CAD programs in penmanship are things
that one can undoubtedly detract from PC programs today; programmed age of Bill of
Material, programmed arrangement in incorporated circuits, disturbance testing, and
numerous others. Computer aided design has enabled the architect to perform designing
estimations. Computer aided design has been a powerful change in the designing business,
where painters, planners and designing jobs are starting to meet up. It didn't eliminate the
entryways, as it associated the entryways and enabled the modelers, architects and specialists.
Computer aided design is only one illustration of the far reaching impacts of registering in the
business. Programming bundles are planned with the assistance of PCs going from 2D vector
composing frameworks to 3D modelers and surface modelers. Present day CAD bundles can
regularly take into consideration a three-dimensional revolution, permitting the perspective
on the item to be produced using any point you need, even from the back to front. Computer
aided design innovation is utilized in the assembling of instruments and hardware and
recorded as a hard copy. Computer aided design is utilized for the point by point innovation
of 3D models and/or 2D drawings of body parts, but at the same time is utilized all through
the designing interaction from applied plan and item configuration, to power and dynamic get
together to clarify the creation strategies for objects. It very well may be utilized to plan
things. Moreover, numerous CAD programs presently offer progressed conveyance and
activity abilities so that specialists can more readily see their item plans.
 Methodology

Our approach to this project was to first understand the basic use of the brake pad, how it
works, its value, the variety and the materials used to make the brakes. We took the
inspiration of our model design from our cars, took some pictures and compared their design
to understand the basic requirements needed to design / produce a pedal brake. Initially new
drawings were drawn to get an idea of its proper structure and visual image that would help
us to create a CAD model for our project. After consultation we finalized our brake design
and modifications, we can make its construction to increase its value without affecting the
integrity of the existing brake structure. The brake history design was done on Solidworks
software, first we built an existing brake on our cars and then we developed a modified
version of that brake logo.
Conclusion
Five different brake pedal design strength analyzes are studied using microscopic analysis.
This analysis revealed that regions of base fatigue failure are associated with higher stress
concentration areas in construction as expected. Analysis reveals that crack launches occur
in areas that are more focused on concentrations which are the thinner strands of the dildo
that makes for more flexible torque. In order to estimate the minimum amount of brake
performance without cracks, the pressure life method is used with the SN diagram of the
material from the manufacturing company. The Gerber method is used to predict pedal
fatigue health. It can be argued that fatigue analysis based on the analysis of static stress
and stressful lifestyle provides a balanced measure of fatigue life of the brake pedals. It is
clear that to maximize the fatigue life of the brake pedal, it is necessary to reduce the
pressure reduction in critical areas. The design of pedal geometry is modified to reduce
stress and improve fatigue life, and after computer analysis and actual testing is performed
under the necessities of the certification standards. As a result, the heaviness was reduced
by 5% and the heavy and heavy brakes were fitted with a heavy and sturdy design that was
useful for reducing vehicle weight and the use of equipment. In the future, light pedals will
be used in the automotive industry. Test bench is good enough to test a new foundation for
hybrid pedals.

Final model of the Brake Pedal