Topology optimization of a MacPherson control arm

One of the most important systems in ground vehicles is the suspension system, which is responsible for the ride comfort, the road holding and handling. A crucial part of a passenger car passive suspension system is the control arm or wishbone arm or A-arm. Its main function is to provide a link between the body of the vehicle and the wheels. In this paper, the studied control arm is a part of a MacPherson strut suspension and its dimensions correspond to a front right suspension of a SUV vehicle. Two geometrical models of the control arm were developed in Solidworks® CAD-CAE Software, one with the measured dimensions and one with the outline dimensions of the control arm. A finite element model of the first one was built, using typical loading conditions, in order to determine the deformation and the stress contours. Then a topology optimization analysis was carried out to the second one in order to obtain a new design for the control arm. The FE results of the existing control arm and the optimized one were compared in terms of weight and structural integrity in different loading conditions leading to conclusions regarding the optimization procedure.