Finite Element Topography and Shape Optimization of a Jounce Bumper Bracket

A case study of the application of topography and shape optimization techniques to the design of a jounce bumper bracket of a pick-up truck has been presented. First a sizing (gage) optimization was undertaken to redesign the jounce bumper bracket. Since the weight was not satisfactory it was decided to try shape optimization. A better solution was obtained. Topography optimization, a relatively new technique of bead formation, was then applied and a still better solution was obtained. All these options were presented to the designer to enable him to make a decision based on manufacturing and other constraints. Although all the three solutions seems to give good results the topography optimized jounce bracket results in the least weight, with the penalty of an additional manufacturing operation.