Topology optimization is a shape optimization method connected with finite element (FE) analysis, and has recently received increasing attention owing to rapid evolution of additive manufacturing (AM). In this study, an automotive knuckle part was developed by combining kinetic analysis, FE structural analysis, and topology optimization. A kinetic analysis based on a multibody dynamics simulation was performed to calculate reaction forces during a given driving course. Structural FE analyses were conducted to evaluate structural safety by applying the calculated reaction forces as boundary conditions. Topology optimization was then carried out to improve the stiffness and structural safety of the knuckle. Further structural FE analyses were performed to compare the structural efficiency of the optimized design where the stiffness increased more than 2.5 times in comparison with the original design. The optimized knuckle pairs were then manufactured by a metal AM process using AlSi10Mg powders, and were assembled to the other suspension components successfully. A formula-style electric car was then built by assembling the developed knuckle, and a number of driving tests showed that the knuckle ensured adequate structural stiffness and safety.

拓扑优化是一种与有限元（FE）分析相关的形状优化方法，近来由于增材制造（AM）的快速发展而受到越来越多的关注。在这项研究中，通过结合动力学分析，有限元结构分析和拓扑优化来开发汽车转向节零件。进行了基于多体动力学模拟的动力学分析，以计算给定行驶过程中的反作用力。通过将计算出的反作用力用作边界条件，进行结构有限元分析以评估结构安全性。然后进行拓扑优化以提高转向节的刚度和结构安全性。进行了进一步的结构有限元分析，以比较优化设计的结构效率，其中刚度与原始设计相比增加了2.5倍以上。然后使用AlSi10Mg粉末通过金属AM工艺制造优化的转向节对，并将其成功装配到其他悬架部件上。然后，通过组装已开发的转向节，制造出了公式式的电动汽车，许多行驶测试表明，转向节确保了足够的结构刚度和安全性。