Topology Optimization and Additive Manufacturing of Automotive Component by Coupling Kinetic and Structural Analyses

Topology optimization is a shape optimization method connected with finite element (FE) analysis, and has recently received increasing attention owing to rapid evolution of additive manufacturing (AM). In this study, an automotive knuckle part was developed by combining kinetic analysis, FE structural analysis, and topology optimization. A kinetic analysis based on a multibody dynamics simulation was performed to calculate reaction forces during a given driving course. Structural FE analyses were conducted to evaluate structural safety by applying the calculated reaction forces as boundary conditions. Topology optimization was then carried out to improve the stiffness and structural safety of the knuckle. Further structural FE analyses were performed to compare the structural efficiency of the optimized design where the stiffness increased more than 2.5 times in comparison with the original design. The optimized knuckle pairs were then manufactured by a metal AM process using AlSi10Mg powders, and were assembled to the other suspension components successfully. A formula-style electric car was then built by assembling the developed knuckle, and a number of driving tests showed that the knuckle ensured adequate structural stiffness and safety.