Design And Performance Study Of A Sedan Suspension Control Arm Based On The Topology Optimization

At present, the finite element analysis is widely used in the research and development of the machinery and auto parts products, but mainly for the performance check of the product. If find that some performance of the product does not meet the design requirements at this time, improving the local design is the best way, however, only based on the design improvements of the method has certain blindness, In case of improved design of the result does not meet design requirements, only returns the starting point to redesign the structure, thus greatly increase the rework, not only extend the development cycle and increase production costs, but reduce the competitiveness of their products. While structure optimization techniques combined use of the finite element analysis and optimization algorithms which can find the best design in the given design requirements; if a problem is found in the virtual pilot phase that the optimization technology can directly give the product improvement program. Application of structural optimization technology can make the structure to meet the design requirements to obtain the optimal scheme and save time and reduce the development cycle.Based on the above reasons, this paper integrated use structural optimization, virtual prototyping, FEA and fatigue life calculation to research on the structure design and performance of a sedan suspension control arm. On the basis of the research results on structural optimization, virtual prototyping, FEA and fatigue life calculation at home and abroad, the paper firstly analyses the hard point load of the control arm. Then the finite element model of the control arm was created with HyperMesh software, and analyzed the finite element strength with the hard point load as the load boundary conditions on the control arm of the original model, and calculated the modal, the structure optimization design of the control arm was carried out, based on the strength and modal analysis results, and the control arm’s improved model of CAD and CAE model were established, based on the optimal results. Finally, calculated the strength and modal of the final control arm’s model, the performance before and after optimization were compared, found that the quality of control arm after structure optimization to reduce by33.55%, the strength and rigidity were increased, and the natural frequency is slightly lower, but still meet the requirements of the dynamic characteristics, and has carried on the fatigue life calculation, the calculation results show that the fatigue life can meet the design requirements.Through the exploration research, this paper has got a complete set of control arm structure optimization design method, made it to change from the simple using of finite element analysis to the comprehensive using of structural optimization, virtual prototype, FEA and fatigue life calculation technology of advanced design method. Not only shortens the development cycle and reduce the production cost, also improve the design level and enhancing the market competitiveness. Therefore, this paper’s conclusions will be reference for structure optimization design of the control arm and development of the automotive parts.