Lightweight Design of Gearbox Housing of Baja Racing Car Based on Topology Optimization

Abstract

In view of the National Undergraduate Baja Contest, an initial model is established for the reducer. According to the calculated force of the transmission part, the reinforcing ribs of the bearing hole are optimized and the initial model is optimized and checked several times using the topology optimization module of ANSYS. The safe and reliable housing model with a weight reduction of 35.82% makes full use of the material properties, thus contributing to lightweight of the whole vehicle under the premise of sufficient strength.

A Review of Topology Optimisation Software for Additive Manufacturing: Capability Comparison

“…In automotive design, topology optimisation can be applied to integrate the lightweight design needed for fuel efficiency and vehicle performance with the stability and strength that geometry must have to withstand drive forces and impact [24]. However, topology optimisation can contribute not only to material or weight savings but also to improving safety components for occupants [18], [21]- [23]. Topology optimisation also proves ideal for implantation design in the medical industry, as they give developers of medical applications complete freedom in the design of shapes and surfaces [29], [32], [33] With a numerically generated examination, errors can occur due to the software itself, but also due to the user implementation.…”

“…Ansys Structural Optimisation module is widely used in the aerospace industries, for example, to develop unibody quadcopters [15], air brake bracing beams [16], and latching components of hatch doors [17]. The module is also intensively applied in the automotive industry (for example, the transmission housing of a Baja racing car [18]).…”

“…Topology optimisation software, whether integrated into software or standalone [12], follows a defined methodological approach that generates a geometrical structure with an optimal density distribution after several iteration runs. In this paper, three topology optimisations included in Ansys Mechanical [13]- [18], Fusion360 [19]- [24], Solidworks Simulate [25]- [29], and stand-alone nTopology [30]- [33] are analysed and compared in terms of implementation and performance capabilities.…”