Independent front suspension lower control arm design with topology optimization approach for electric light-duty vehicle

750 kg load-carrying capacity and, 1000 kg towing capacity of a two-wheel drive, two-axle electric light-duty vehicle with double wishbone independent front suspension has been designed using a topology optimization approach. For this purpose, firstly, the kinematic model of the suspension system and steering system was developed using the multi-body dynamics approach. Using this model, the force and moment values acting on the connection points were defined separately for the quasistatic load cases mentioned in the literature such as braking, cornering, bumping and brake in cornering. In the second step, a preliminary design model of the lower control arm was created, considering the defined positions of the wheel sweep volume, the suspension spring and the brake system components. In the third step, structural static analysis was performed for each load case and the results obtained were used as inputs for topology optimization. This allowed for the identification of non-load-bearing volumetric elements for each load case. In the fourth stage, the volumetric structures obtained from the topology optimization studies were overlaid at the same coordinates, and a manufacturable solid model of the swing arm was designed using reverse engineering. In the final stage, structural static analysis was performed to verify the final design and calculate the minimum safety factor. As a result of the optimization study for the swing arm, planned to be manufactured using 6061-T6 aluminum alloy, a product with 46% less weight and a safety factor of 1.21 was achieved.