Modelling and Structural Optimization of Upper Control Arm Using FEA

Abstract

In the quest for reduced vehicle mass without sacrificed integrity, Computer Aided Engineering (CAE) topology optimization software was investigated and utilized in the design of the Indian Formula 1vehicle as a means to determine the optimum material distribution within a component for a given set of loading and boundary conditions.

This paper looks at the design of a rear suspension control arm component using modern topology optimization techniques and compares the end product to that of the 2005 model control arm component, which was designed using more traditional techniques.A hydraulic load cell system was created to simulate the vehicle suspension forces and was used to physically test the original and optimized parts to failure. Through the use of Altair OptiStruct® topology optimization software, the same hydraulic loads are applied to the virtual component and checked the results.

Control arm is designed in 3d modeling software then imported in to Altair Hypermesh for preprocessing; to solve Altair Radioss is used. Altair Optistruct is used for optimum material distribution in the component to get weight reduction. After getting reduced component from Optistruct again modified model is analyzed by using same loads and constraints. First step will solve static analysis and second step is to reduce the weight of the component topology optimization methodology is used with the help of Altair Optistruct software. After optimization a weight savings of 42% coupled with an increase in yield strength of 29.7% was realized in the optimized design of the Control Arm.