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Topology Optimization and Additive Manufacturing of Automotive Component by Coupling Kinetic and Structural Analyses

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Abstract

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.

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Abbreviations

t :

side thickness of the knuckle, mm

F V :

vertical force, N

F H :

horizontal force, N

m f :

mass of the front part

m 0 :

mass of the knuckle for the initial design

m :

mass of the knuckle for a design change

δ f :

maximum deformation of the knuckle

k* :

relative stiffness of the knuckle

λ :

safety factor based on the fatigue strength

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Acknowledgement

This work was supported by the Korea Institute of Machinery & Materials grant (Grant no.: NK224I) and the National Research Foundation of Korea (NRF) grant (Grant no.: 2019R1A2C1002799) funded by the by the Ministry of Science and ICT, Republic of Korea. The authors also thank to Mr. Sunwoo Jin at Hyundai Rotem Co. Ltd. for his support with kinetic analysis.

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  1. Department of Mechanical System Design Engineering, Seoul National University of Science & Technology, Seoul, 01811, Korea

    Gyu-Won Kim, Yeong-Il Park & Keun Park

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  1. Gyu-Won Kim
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  2. Yeong-Il Park
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  3. Keun Park
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Correspondence to Keun Park.

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Kim, GW., Park, YI. & Park, K. Topology Optimization and Additive Manufacturing of Automotive Component by Coupling Kinetic and Structural Analyses. Int.J Automot. Technol. 21, 1455–1463 (2020). https://doi.org/10.1007/s12239-020-0137-1

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  • DOI: https://doi.org/10.1007/s12239-020-0137-1

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