Abstract
This paper deals with the design of an upright using a topological optimization. This type of optimization is a relatively young and rapidly evolving area of computational mechanics that seeks to make multiple material savings that cannot be achieved by conventional methods. The optimized upright was utilized in a fully functional prototype of the student formula within the Formula Student competition. The main objective of the optimization was to meet the requirements of the physical properties, weight, stiffness, and strength of the upright. The initial model of the upright was iteratively optimized using topological optimization and a finite element static analysis to obtain the final model. Using the finite element analysis, its behavior in operation within individual load cases was predicted. Symmetry was used to mirror the finished model to obtain the opposite upright of the other side of the car. Finally, the topologically optimized upright was compared with an upright made by conventional methods.
Highlights
The racing car life cycle is very short, and designers are always under pressure because of expenses, design innovations, material requirements, and precise manufacturing
The upright is one of the main components of the formula suspension system, and due to the fact that this is a component that has a major impact on the unsprung weight, which directly affects the driving properties, it is very desirable that its weight be as low as possible [2]
The principle of topology optimization can be explained by way of the example in Figure 3, where we want to determine the volume of supportive structure needed to support a homogeneously
Summary
The racing car life cycle is very short, and designers are always under pressure because of expenses, design innovations, material requirements, and precise manufacturing. To successfully cope with a task such as the topology optimization of an upright, knowledge on the design of accurate machine components is necessary. Both theoretical and practical knowledge of additive manufacturing is necessary. 1970s, many optimization methods have been developed during intensive research topological optimization. Most remained only onon thethe theoretical level due to lack of computational topological optimization. Each representing a different approach to the solution, have been putput to to power. Each representing a different approach to the solution, have been practical useuse in the solution of material distribution [7,8,9]
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