Structural Optimization: Achieving a Robust and Light-Weight Design of Automotive Components

Developing automotive vehicles and components to achieve light-weight designs and to meet design targets on structural stiffness, modal frequencies, durability, and crashworthiness, can no longer be driven by a “trial-and-error”strategy. Structural optimization tools provide the necessary analyses during the initial stages of vehicle development to arrive at the most efficient and effective designs. In this paper, we illustrate the importance of topological and gage optimization in achieving mass reduction without compromising on the structural requirements through three design examples. The examples involve a transfer case assembly, a shock reinforcement assembly for a truck frame, and a step-bar module.