Comprehensive view on racing car upright design and manufacturing

Abstract

This paper deals with the design of an upright using a topological optimization. This type of optimization is a relatively young and rapidly evolving area of computational mechanics that seeks to make multiple material savings that cannot be achieved by conventional methods. The optimized upright was utilized in a fully functional prototype of the student formula within the Formula Student competition. The main objective of the optimization was to meet the requirements of the physical properties, weight, stiffness, and strength of the upright. The initial model of the upright was iteratively optimized using topological optimization and a finite element static analysis to obtain the final model. Using the finite element analysis, its behavior in operation within individual load cases was predicted. Symmetry was used to mirror the finished model to obtain the opposite upright of the other side of the car. Finally, the topologically optimized upright was compared with an upright made by conventional methods.