Design of An Upper-Control Arm using Shape Optimization

A case study of an application of shape optimization techniques in the design of an upper control arm of an automotive suspension system has been presented. An existing design of an upper control arm had high stresses and low fundamental frequency. The designer's inputs as to the various possible shape changes, constraints of movements etc. were built into the optimizer as shape variables and constraints. Shape optimization was then performed using approximate direct linearization method of MSC/NASTRAN software. A number of design directions were obtained. With a 24% weight penalty the first frequency was raised to 834 Hz. and brought closer to the target of 900Hz. and the stresses were also brought down by 30%.