Analysis, Design, and Topology Optimization for Multi-Link Suspension Components for a Cadillac LYRIQ EcoCAR EV

As electric vehicles (EVs) continue to grow in both popularity and innovation, most areas focus on the integration of EV powertrains both electrically and mechanically. This leaves the rest of the vehicle to be open to even more improvements, especially in the area of lightweighting. Most explorations in lightweighting involve minimizing a vehicle’s sprung mass. This may include involving lighter materials such as fiberglass or aluminum on body panelling, or using lighter plastics in the interior. While it is prudent to target lighter weight on components being supported by the suspension, lightweighting suspension components themselves can also be worth investigating. As EVs and especially EV SUVs continue to include new features and creature comforts, their mass increases and their suspension grows more and more complex, even making departures from conventional automotive suspension design. This paper will investigate the analysis, design, and application of CAE and topology optimization to lightweight a crucial component in a 2023 Cadillac LYRIQ EV, the suspension fork. When present, the suspension fork is crucial in joining the strut tower assembly to the lower control arm on the front suspension. The fork is responsible for enduring loads from both sprung and unsprung components and transferring loads from the top of the strut tower to the bottom. Its design may also have an impact on driving dynamics. To complete this study, it is crucial to create correct load cases with data obtained using a multi-body dynamics model using software such as Altair MotionSolve, completing FEA in Siemens Simcenter, and topology optimization in Autodesk Fusion 360. While topology optimization is possible, this paper will also investigate the feasibility of manufacturing parts that are designed this way for mass market production.