Generative design and analysis of a double-wishbone suspension assembly: a methodology for developing constraint oriented solutions for optimum material distribution

Abstract

Purpose The purpose of this paper is to implement the generative design as an optimization technique to achieve a reasonable trade-off between weight and reliability for the control arm plate of a double-wishbone suspension assembly of a Formula Student race car. Design/methodology/approach The generative design methodology is applied to develop a low-weight design alternative to a standard control arm plate design. A static stress simulation and a fatigue life study are developed to assess the response of the plate against the loading criteria and to ensure that the plate sustains the theoretically determined number of loading cycles. Findings The approach implemented provides a justifiable outcome for a weight-factor of safety trade-off. In addition to optimal material distribution, the generative design methodology provides several design outcomes, for different materials and fabrication techniques. This enables the selection of the best possible outcome for several structural requirements. Research limitations/implications This technique can be used for applications with pre-defined constraints, such as packaging and loading, usually observed in load-bearing components developed in the automotive and aerospace sectors of the manufacturing industry. Practical implications Using this technique can provide an alternative design solution to long periods spent in the design phase, because of its ability to generate several possible outcomes in just a fraction of time. Originality/value The proposed research provides a means of developing optimized designs and provides techniques in which the design developed and chosen can be structurally analyzed.