Abstract
Control Arm (CA) of a suspension plays an important role in the automotive ride comfort and handling stability. In this paper, the topology optimization model including ball joints and bushing for topology optimization of an aluminium CA is established, where a ball joint is simplified as rigid elements and the elastic properties of a rubber bushing are estimated using Mooney-Rivlin constitutive law. A method for treating with multiple loads in topology optimization of CA is presented. Inertia relief theory is employed in the FEA model of the CA in order to simulate the large displacement motion characteristics of the CA. A CA is designed based on the topology optimization results, and the strength, natural frequency, and rigidity of the optimized CA are calculated. The calculated results show that the performances of the optimized CA with the proposed model meet the predetermined requirements.
Highlights
Control Arm (CA) is an important component of the suspension system for the automotive ride comfort and handling stability
The transfer of the topology optimization result into a practical design needs lots of manual interference, such as geometry recovery or shape optimization to obtain further improvement [13]
This paper presents a procedure for the topology optimization design of the CA in the automotive suspension system
Summary
Control Arm (CA) is an important component of the suspension system for the automotive ride comfort and handling stability. Solutions obtained by size and shape optimization methods keep the same topology of the initial design. Lee [6] utilize topology and shape optimization methods in the design stage of an aluminium Control Arm for an automotive suspension. Yang et al [8] present and discuss new applications of topology optimization including weight reduction, manufacturing process selection, weld, and bead pattern designs for some three-dimensional automotive components. In the above literature, the effects of ball joints and bushings on the performances of a CA are not considered and only taken them as fixed constraints in the FEA model of the CA. The CA is designed based on the topology optimization methods proposed in this paper, and the strength, natural frequency, and rigidity of the optimized CA are calculated. In comparison with the traditional CA model without consideration of the functionality of the ball joints and bushings, it is concluded that the proposed CA model can more describe the operating characteristics of the CA
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