Topology optimization of a formula student upright for mass reduction and structural performance assessment

Abstract

In Formula-type racing cars, reducing unsprung mass is one of the critical design objectives for improving performance. As key components of the suspension system, the uprights must be designed to be both lightweight and durable, given that they are subjected to high mechanical loads and directly influence the car’s dynamics. This study aims to redesign the front upright section used in Formula Student vehicles using a topology optimization approach and to evaluate the structural performance of the optimized designs. Within the scope of the study, optimized designs with different material reduction ratios were obtained based on the existing upright geometry, and these designs were compared in terms of their structural behavior. In the optimization process, material reductions of 30%, 50%, and 70% were applied, and the resulting models were examined according to the criteria of maximum stress and total deformation. Aluminum 7075-T6 alloy was preferred due to its high strength-to-weight ratio. The results showed that topology optimization could provide a significant mass reduction in the upright component. Although increases in stress and strain values were observed with increasing material reduction ratios, it was determined that optimized designs remained within acceptable safety limits. In particular, it was found that moderate material reduction ratios offered a balanced solution between weight savings and structural durability. The findings reveal that topology optimization is an effective design method for developing lightweight, durable, and high-performance suspension components in Formula Student and similar racing cars.