Product Re-Engineering by Topology Optimization for Forged Component

Optimization tools are used when a set of objectives is used to find the best alternative proposed design. Topology optimization adds a whole new level of process of developing creative design space. The objective of topology design is to obtain a material distribution inside a given design space that is optimum in this aspect. Material is rearranged and elements that are not necessary from an objective point of view are eliminated throughout the optimization process. For Topology optimization of the forged component which is selected from industry which is steering knuckle assembly is optimized and presented in this study. For topology optimization, platform such as 3D experience is used to simulate the part. A number of modules from 3D experience is used for FEA analysis, mesh-smoothening techniques and creating parametric geometry in terms of shape and explored in way to produce the topology geometry more functional. Functional Generative Design module is used for topology optimization. From this study overall weight reduction is achieved after using the finite element method to analyze a steering knuckle assembly and performing topology optimization. And the part is optimized in terms of shape and for further suitable manufacturing process. According to the result of this research, 64% relative weight reduction is achieved in respect to a given target is 50%. The original weight of the knuckle was 843 gm. however it has since been reduced to 513 gm. As a result, the cost of knuckle is lowered.