Topological optimization of the fork-end of a knuckle joint

Topology optimization is a mathematical approach that optimizes the layout for the given design constraints such as loading and boundary conditions so that the optimum design obtained performs its function. In different types of loading conditions such as single load or multiple load topological optimization result in the best use of a material for a body in given volume constraints. In topological optimization the structural compliance is minimized while satisfying a constraint on the volume of the structure. This paper represents the topological optimization of the fork-end (double eye) of a knuckle joint with the objective to reduce the mass of an existing fork-end of a knuckle joint of an automobile or locomotive by applying the optimization technique. Reducing the weight of an automobile part will result in the overall weight reduction of a vehicle, thus, its energy consumption demands decrease thereby improving its fuel efficiency. The topological optimization was done using a finite element solver, ANSYS. The ANSYS Parametric Design Language was employed for utilizing the topological optimization capabilities of the commonly used finite element solver ANSYS. Solid92 elements were used to model and mesh the fork end of the knuckle joint in ANSYS. The optimality criteria method was used for topological optimizing the fork end of a knuckle joint.