As the global automotive industry increasingly prioritizes electrification and long-term sustainability, the demand for aggressive lightweighting in automotive chassis engineering has intensified. This study presents a process-driven, multi-stage structural optimization workflow designed to maximize total mass reduction while maintaining rigorous structural performance. To mitigate the high computational costs and software license overhead of nonlinear Finite Element (FE) analysis, the methodology transforms complex models into efficient linear representations. This strategic shift preserves critical structural behaviors while significantly enhancing license efficiency and total computational simulation throughput.
The novelty of this workflow lies in an integrated optimization loop that begins with Topology Optimization to define primary load paths, followed by Free Shape Optimization to mitigate stress concentrations. By embedding manufacturing constraints such as draft angles and minimum thickness directly into the optimization process, the methodology effectively eliminates traditional redesign cycles. Optimized designs are then seamlessly translated into CAD via advanced ANSA tools for validation of von Mises stress, plastic strain, and buckling. This synchronized transition from analysis to realization reduced the development cycle by 50%, enabling a design freeze significantly faster than conventional methods.
The integrated approach achieved a 15% mass reduction while meeting all functional durability and crash requirements. Given that a 1% reduction in mass correlates directly to a 1% reduction in CO2 emissions, the resulting design substantially minimizes the vehicle's total carbon footprint. By lowering material consumption and maximizing computational efficiency, this study offers a repeatable solution for balancing simulation fidelity with the urgent demands of modern sustainable automotive design.