The Topological Optimization and the Design for Additive Manufacturing of a Steering Knuckle for Formula SAE Electric Vehicle

Abstract

Formula Student represents the main motorsport activity for future professionals during their academic preparation. There is intensive migration from the prototypes with an internal combustion engine to electrical vehicles. The challenge of electric vehicles is the weight of the batteries which has to be compensated. The Topological Optimization process represents a method of removing volume and mass of the component (elements of mesh) with the aid of the discretization allowed by the finite element method (FEM) until a mass or stress constraint is attained. The results come in a complex shape, the material being kept only in the stressstrain directions. The manufacturing process is usually as complex, being employed high complexity technologies such as Selective Laser Melting (SLM). Improved strength-to-weight ratio materials are to be considered to obtain the most performant design of a specific component. The present paper presents the topological optimization process of the steering knuckle for the Formula Student electric vehicle of ART-TU Team of Technical University of Cluj-Napoca. It means that the part is simulated and optimized through Ansys Static Structural and there is done post-processing of the component along with Data Validation. The conclusions consist of the viability of the Topological Optimization process when designing complex components for performance automotive.