Topology optimization of the front steering knuckle structure of a formula SAE racing car

Ramirez A.; Yactayo C.E.; Rodriguez C.V.; de La Torre D. · International Journal of Automotive and Mechanical Engineering (2026) · DOI: 10.15282/ijame.23.1.2026.12.1010

Resumen

The Formula SAE (FSAE) competition is an international student event that seeks to design a lightweight single-seater to maximize performance. In this context, the front steering knuckle represents a significant challenge, as its weight directly influences the vehicle's dynamic performance. However, previous studies have limitations regarding the combined use of topology optimization tools and the evaluation of new materials for this component. This research addresses this gap by topologically optimizing the front steering knuckle of an FSAE single-seater to reduce its weight while maintaining its structural strength. Initially, the stresses at the knuckle's support points were calculated, considering Formula SAE regulations and the vehicle's operational conditions (acceleration, braking, cornering, and overcoming obstacles). The knuckle was modeled in SolidWorks, and its structural parameters (stress, deformation, and factor of safety) were analyzed in ANSYS using lightweight and durable materials such as Aluminum 7075-T6 and Alumold, the latter being analyzed for the first time in this context. Finite element analysis was performed, and a suitable mesh was selected from six options. Subsequently, topology optimization was applied to remove unnecessary material using ANSYS and SolidWorks software, reducing the initial knuckle mass of 2.41 kg by 35% and 25%, respectively, while maintaining a minimum factor of safety of 1.5. This approach demonstrates the effectiveness of topology optimization in enhancing the structural design of automotive components.

Instituciones: Universidad Nacional de Ingeniería; Universidad Tecnológica del Perú