Double Optimization Design of the Formula Racing Car Frame Based on the Variable Density Method and the Joint Variable Method

Abstract

In the Formula Student Racing Car, the frame is a fundamental component that supports the body. The frame’s anti-deformation ability will impact the four-wheel positioning parameters of the car, which subsequently affect the car’s stability. The quality of the frame directly determines the power and efficiency of the racing car, making the frame crucial to the overall race performance. Therefore, researching lightweight frame design is particularly important to enhance frame performance and reduce its total weight. In this paper, based on the variable density method, the global topology optimization of the frame is carried out to obtain the distribution of the frame material, realize the efficient utilization of the material, and improve the torsional stiffness of the frame. Compared with the previous local topology optimization, the global topology optimization involves a wider range, and the results are more accurate. Based on the adjoint variable method, the sensitivity analysis of the frame is carried out to obtain the influence level of each design variable. The size of the frame is optimized according to the variables with high influence levels. After optimization, the total mass of the frame is reduced by 12.8%; the performance in terms of maximum displacement and maximum stress is improved; and the lightweight design of the frame is realized as a whole.