Shape optimization of a control arm produced by additive manufacturing with fiber reinforcement

Abstract

Additive manufacturing makes possible to overcome the limitations of subtractive manufacturing and supposes a transformation with respect to the traditional processes, allowing to manufacture complex geometries by controlled deposition of material. In the automotive industry, the application of continuous fiber reinforcement, in combination with shape optimization for additive manufacturing, can produce parts with higher mechanical performance. This paper reports the shape optimization problem of a suspension control arm to be produced by additive manufacturing with fiber reinforcement, using finite element analysis. First, the current material, loading conditions and constraints to which the control arm is subjected were determined, considering its traditional design. Then, a numerical model of the part was developed considering its current material and shape to obtain the total deformation and von Mises stress distributions. Afterwards, the new material model was defined, and the shape optimization was performed with the goal of maximizing stiffness. Finally, the results from the optimization process were validated by manufacturing and testing the part.