Structural optimization concept for the design of an aluminium control arm

Abstract

The development of a mechanical structure needs to be started from the conceptual design with low cost, high performance and quality. In this regard, the structural and topological shape of the system has a great e ect on the performance in terms of rigidity, strength and mass reduction. In this paper, optimization design methodologies in the design stages of an aluminium control arm for a suspension are presented. First, using topology optimization, the optimal layout and the reinforcement structure are obtained, and then the detail designs are carried out using shape optimization for the structural rigidity and strength. In comparison with a steel control arm, the mass reduction is 50 per cent and the structural rigidity and strength are improved up to 40 per cent.