Topological optimization of the load-bearing structure of the safety cage

Abstract

BACKGROUND: The conducted study of the stress-strain state of the safety cage developed in compliance with the requirements of the Russian Automotive Federation (RAF) showed that the structure does not meet the requirements of deformation after side impact. Therefore, the basic design demands additional study with the use of state-of-the-art approaches of development.
 AIMS: This paper considers the issue of finding the optimal design of a racing car safety cage based on topological optimization in order to meet the rigidity requirements while minimizing the mass.
 METHODS: To implement the topological optimization method, mathematical modeling was carried out using the Structural Optimization module of the Ansys software package. Tests regulated by the RAF were selected to test the effectiveness of the optimized design. To evaluate the results, a comparison of the results of test simulation before and after optimization was made.
 RESULTS: The mass of the optimized design has decreased by 6% relative to the original. Rigidity of the structure with loading at main and front rollbars remained the same. Deformation of the optimized design with side loading of the main rollbar was reduced by 98%.
 CONCLUSIONS: The results of modeling the tests regulated by the RAF showed that the design of the safety cage, developed on the basis of the material pseudo-density map obtained as a result of topological optimization, meets the requirements for permissible deformation. Further study of the stress-strain state of the safety cage should be carried out in conjunction with the finite element model of the vehicle to take into account the loads arising as a result of body deformation.