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Copyright 1999 by the American Foundrymens Society 1 A Design Study in Aluminum Casting The Brake Pedal for the Chevrolet Corvette Study Outline  Introduction  Choosing a Molding Method  Selecting an Aluminum Alloy  Developing Casting Soundness  Controlling the Metal Flow  Insuring Quality  Summary Acknowledgement -- The metalcasting design studies  are a joint effort of the American Foundrymens Society and the Steel Founders Society of America. Project funding was provided by the American Metal Casting Consortium Project, which is sponsored by the Defense Logistics Agency, Attn: DLSC-T, Ft. Belvoir, VA 22060-6221 Start the Design Study Copyright 1999 by the American Foundrymens Society 2 An Example in Aluminum Casting Brake Pedals for the Corvette Sports Car  The Application -- The Chevrolet Corvette is a world-class sports car with outstanding road performance and unique styling. In designing the Corvette, General Motors engineers had the mandate to develop a vehicle design that communicated unrivaled performance and style, while reducing weight for fuel efficiency and acceleration. One component of the interior design is the  brake pedal. The brake pedal was originally designed as a welded steel assembly that was heavy and required finish treatments for appearance.  Component Description -- The brake pedal in the Corvette is designed as a offset bar approximately 15" long with an integral foot pad (with four slots on the face) on one end of the pedal bar.    The opposite end of the bar has a perpendicular pivot cylinder for mounting and rotation.  On the under side of the bar there is a pocket in which the brake actuator rod sits with a pivot pin Functionally, the brake pedal has to be a high strength component  (35 ksi tensile strength and 25 ksi yield strength) with high ductility (7%). The appearance of the foot pad and the visible section of th ...
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