Shape Optimization Application in Upper Control Arm Design

A case study of an application of shape optimization techniques in the design of an upper control arm of an automotive suspension system has been presented. An existing design of an upper control arm was taken as a starting design point. The designer's inputs as to the various possible changes, constraints of movements etc. were built into the optimizer as shape variables and constraints. Shape optimization was then performed using approximate direct linearization method of MSC/Nastran software. A number of design directions were obtained. The weight of the upper control arm was reduced by 15% and at the same time the maximum stresses were also reduced by 29%.