Design and Topological Optimization of a Wheel Upright Using Finite Element Analysis

Uprights are one of the most critical structural elements in vehicles suspension systems. A standard upright serves as a physical mounting for the wheel hub and brake components as well as links the axle to the control arms. Uprights are relatively bulky by design to withstand the significant loads they observe during vehicle braking, maneuvering, and driving on rough terrain. In automotive design, specifically, race car design, utilizing lightweight components and reducing fuel consumption are imperative. This weight reduction-based paradigm is being adopted by the car industry at large, particularly due to the shift towards automotive electrification. Consequently, this work investigates the potential for using topological optimization to reduce the bulkiness and weight of uprights without compromising their structural integrity and reliability. An upright designed for a racing car is selected in this study. Topological optimization is performed on the upright using the finite element software ANSYS. Results show that a considerably enhanced upright is obtained after 48 topological optimization iterations while maintaining a factor of safety of 2.5. The optimized upright exhibited less stress concentrations and 39% lesser weight than the original upright.