Design Enhancement of Automotive Console Armrest Structure Utilizing Finite Element Analysis-Based Topology Optimization

This paper investigates the structural integrity of a center console armrest structure for a four-wheeler automobile. The present analysis investigates to reduce the mass of the armrest structure without compromising the structural integrity of the armrest model. Various loading conditions are employed to study the effects on the structure. Finite element analysis (FEA) approach is utilized to study the effects of various loading conditions on the structure. Topology optimization technique is employed to reduce the mass. The design criteria followed to achieve the mass reduction are kept in check by considering the global von-mises stress criterion, designable and non-designable areas of the structure. Linear structural analysis is conducted with Multipoint constraint (MPC) contacts, 3D solid higher order tetrahedral and hexahedral elements and beam elements to perform the FEA analysis. Sequential Convex Programming (SCP) method is employed in topology optimization for performing the analysis. The topology optimization simulation suggests that, the weight of the structure can be reduced by 82.17 %. The optimized design is further utilized for same loading conditions and it is found that it can sustain the load applied to the armrest assembly. The improvement in the design helped in reduction of weight and cost of the material. The enhanced design can be further utilized for other functionalities and can perform efficiently.