Design, analysis and topology optimization of a car’s suspension lower control arm

Abstract. The modern automotive industry aims to design durable yet lightweight components that meet high performance and material efficiency goals, utilizing technologies like metal 3D printing. This study focuses on the design, analysis, and topology optimization of a MacPherson-type lower control arm, with a particular emphasis on static analysis and mass reduction achieved through topology optimization. The design process began with reverse engineering an existing control arm to acquire basic dimensions, followed by the development of a new model in SolidWorks. SolidWorks Simulation tools were employed for both stress analysis and topology optimization. The analysis considered the four primary stress forces, applied both parallel and perpendicular to the vehicle's longitudinal axis. The forces were calculated using basic mechanics and vehicle dynamics formulas, and the results were examined through finite element analysis (FEA), capturing Von Mises stresses. The selected materials were aluminum 7075-T6 and titanium Ti-6Al-4V, both suitable for 3D printing. The highest stresses (196 MPa) occurred during braking at maximum speed, and based on this scenario, topology optimization was performed. The optimized arm achieved a mass reduction of 38% compared to the non-optimized model, with SolidWorks Simulation used to evaluate mass reduction, strength retention, and fatigue analysis based on material type, underscoring the benefits of this approach.