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Since its advent in the years 1960's, finite element analysis (FEA) has been the main tool for industries to assess components and systems failure and physical behavior. Increased computational resources, the maturity of software packages and the need for more complex applications have contributed to add new resources to the finite element scenario. One of the most interesting of those new features is structural optimization, which takes product development to a whole new level by reducing material costs while considering geometrical and manufacturing constraints. In the present paper, structural optimization is used as a tool to develop a new lever arm for clutch release bearings. Among the design constraints, geometric restraints as well as loading and contact interfaces were considered.

The basic function of the clutch, transmitting torque when running, interrupting the flow of power between the engine and gearbox in the changing gears and stopping and protecting the engine and transmission against overload and dampen vibration transmission. The plateau clutch with spring membrane is the system used today. The modern clutches are small and save space in the engine compartment reducing the total weight of transmission, minimizing the resistance to rotation of the motor, providing less mechanical losses. The construction and assembly of the membrane spring clutch assembly is very important, since misalignment of reeds could result in chatter or vibration in clutch pedal, along with the hard drive of the pedal, which can also generate a deformation of the components and thus premature wear of the clutch.