This content is not included in
your SAE MOBILUS subscription, or you are not logged in.
Control Arm Design Utilizing Multi-Material Topology Optimization
Technical Paper
2021-01-0826
ISSN: 0148-7191, e-ISSN: 2688-3627
This content contains downloadable datasets
Annotation ability available
Sector:
Event:
SAE WCX Digital Summit
Language:
English
Abstract
With the rising cost of fuels in addition to stricter emission standards, modern vehicles ought to be more fuel efficient. The best approach to increase fuel efficiency is to reduce the mass of vehicles. In order to produce light weight components for vehicles, topology optimization (TO) is now widely used by designers. However, the raw results obtained from TO cannot be manufactured directly and require significant reinterpretation to be able to be manufactured using traditional manufacturing processes. By considering the manufacturing process outside of TO, a sub-optimal design is obtained. The consideration of process specific manufacturing constraints within the TO ensures that a more optimal design will be produced. Previously the complex designs produced by TO have been a barrier to its implementation as the components cannot be produced without excessive costs. By coupling manufacturing constraints with TO more optimal designs can be obtained.
Traditionally TO is done with a single material (SMTO) to arrive at the optimal geometry for that material. Within the automotive industry, designs are typically dominated by steel but aluminum is becoming more common. With the objective to create lighter components for vehicles many other materials have been experimented with. The introduction of multi material topology optimization (MMTO) has allowed for the simultaneous optimization of material placement and material selection. By producing designs with multiple materials, the benefits of each material can be combined to produce the best design.
To show the application of these powerful tools, an MMTO design space was created for an automotive control arm. The design was optimized with steel and aluminum materials to minimize the compliance of the component. This will provide the most structurally efficient control arm for the target design mass. When matching the mass of a conventional stamped control arm, design compliance reductions of up to 70.6% were found for typical MMTO, without manufacturing constraints. Applying manufacturing constraints resulted in compliance falling by up to 62.2% and 23.7%, compared to the conventional design, for extrusion and casting respectively. Within the optimization material ratio constraints are implemented to limit the usage of higher cost materials.
Recommended Content
Authors
Topic
Citation
Forward, C., Shah, V., Kashanian, K., Pamwar, M. et al., "Control Arm Design Utilizing Multi-Material Topology Optimization," SAE Technical Paper 2021-01-0826, 2021, https://doi.org/10.4271/2021-01-0826.Data Sets - Support Documents
Title | Description | Download |
---|---|---|
Unnamed Dataset 1 | ||
Unnamed Dataset 2 |
Also In
References
- Bendsøe , M.P. , and Kikuchi , N. Generating Optimal Topologies in Structural Design Using a Homogenization Method Comput. Methods Appl. Mech. Eng. 71 2 197 224 1988 10.1016/0045-7825(88)90086-2
- Cavazzuti , M. , Baldini , A. , Bertocchi , E. , Costi , D. et al. High Performance Automotive Chassis Design: a Topology Optimization Based Approach Struct. Multidiscip. Optim. 44 1 45 56 2011 10.1007/s00158-010-0578-7
- Warwick , B.T. , Mechefske , C.K. , and Kim , I.Y. Topology Optimization of a Pre-Stiffened Aircraft Bulkhead Struct. Multidiscip. Optim. 60 4 1667 1685 2019 10.1007/s00158-019-02284-w
- Li , D. , and Kim , I.Y. Multi-Material Topology Optimization for Practical Lightweight Design Struct. Multidiscip. Optim. 58 3 1081 1094 2018 10.1007/s00158-018-1953-z
- Vierhout , G. , Roper , S. , Li , D. , Sangha , B. et al. Multi-Material Topology Optimization: A Practical Method for Efficient Material Selection and Design SAE Technical Paper 2019-01-0809 2019 https://doi.org/10.4271/2019-01-0809
- Roper , S. , Li , D. , Florea , V. , Woischwill , C. , and Kim , I.Y. Multi-Material Topology Optimization: A Practical Approach and Application SAE Technical Paper 2018-01-0110 2018 https://doi.org/10.4271/2018-01-0110
- Harzheim , L. , and Graf , G. A Review of Optimization of Cast Parts Using Topology Optimization Struct. Multidiscip. Optim. 30 6 491 497 2005 10.1007/s00158-005-0553-x
- Shah , V. , Kashanian , K. , Pamwar , M. , Sangha , B. , and Kim , I.Y. Multi-Material Topology Optimization Considering Manufacturing Constraints SAE Technical Paper 2020-01-0628 2020 https://doi.org/10.4271/2020-01-0628
- Vatanabe , S.L. , Lippi , T.N. , de Lima , C.R. , Paulino , G.H. , and Silva , E.C.N. Topology Optimization with Manufacturing Constraints: A Unified Projection-Based Approach Adv. Eng. Softw. 100 97 112 2016 10.1016/j.advengsoft.2016.07.002
- Kashanian , K. , Shah , V. , Pamwar , M. , Sangha , B. , and Kim , I.Y. Motorcycle Chassis Design Utilizing Multi-Material Topology Optimization SAE Technical Paper 2020-01-0509 2020 https://doi.org/10.4271/2020-01-0509
- Li , C. , and Kim , I.Y. Multi-Material Topology Optimization for Automotive Design Problems Proc. Inst. Mech. Eng. Part D J. Automob. Eng. 232 14 1950 1969 2018 10.1177/0954407017737901
- Bendsøe , M.P. , and Sigmund , O. Material Interpolation Schemes in Topology Optimization Arch. Appl. Mech. Ingenieur Arch 69 9-10 635 654 1999 10.1007/s004190050248
- Zhou , M. , Shyy , Y.K. , and Thomas , H.L. Checkerboard and Minimum Member Size Control in Topology Optimization Struct. Multidiscip. Optim. 21 2 152 158 2001 10.1007/s001580050179
- Zhou , H. , Zhang , J. , Zhou , Y. , and Saitou , K. Multi-Component Topology Optimization for Die Casting (MTO-D) Struct. Multidiscip. Optim. 60 6 2265 2279 2019 10.1007/s00158-019-02317-4