Fail-Safe Mass Reduction of a Heavy-Duty Front Axle Using Topology Optimisation

Abstract

A Topology Optimization and Design of Experiments (DoE) based mass reduction process for the rigid front axle of an in-use heavy commercial vehicle is summarized. Finite Element (FE) analyses were performed to determine the stress concentration regions of the axle beam for different loading conditions.  Then, topology optimization was used to determine the regions where mass reduction is possible under critical loading condition.  According to the results of the analyses, design parameters for the form and location of the holes were determined.  A parametric study was carried out on the axle beam using the DoE-Response Surface Methodology (RSM) approach.  The failure potential of these holes was evaluated with the help of Goodman-Haigh diagram. The results showed that the total mass can be reduced by 14.2% without creating a new failure mode. Considering the annual production capacity of the axle studied, it is seen that approximately 8,000 additional axle beams can be produced using the same amount of material.