Topology Optimization and Strength Performance Analysis of a Lower Control Arm Sedan Suspension Part

Abstract

The selection of an excellent vehicle includes the safety and comfort of passengers which a suspension system provides. The suspension system of a sedan usually consists of control arms, coil spring, and struts. In a sedan-type vehicle, a lower control arm is considered as the most important part of a suspension system because this prevents the wheels from misaligning and separating from the vehicle body. The lower control arm used as subject in this study is a commercially installed lower control arm in a MacPherson strut assembly on a Toyota sedan model – the Vios 2017. In this study, the control arm models are modeled and simulated through Autodesk Fusion 360's CAD/CAE function and topology optimization techniques to reduce the weight and volume. The sprung and unsprung weights are considered in this study as load cases to simulate the redesigned and own design lower control arm model on a flat terrain condition. Static stress analysis is used to generate the design matrix consisting of four parameters namely the deformation, yield stress, safety factor and percent weight reduction on the redesigned models. Topology optimization is achieved through numerous simulations involving changing the shapes and positions of the cut out areas in the lower control arm models.