The Use Of Topology Optimization In Enhancing Structural Property Of An Automotive Front Sub-Frame

Author

Da’quan Prince- Floyd, Prairie View A&M University

Date of Award

5-2022

Document Type

Thesis

Degree Name

Master of Science

Department

Mechanical Engineering

Abstract

Structural optimization techniques have advanced the efficiency and durability of automotive structures. Automotive parts such as engine mounts, chassis, and sub-frames have complex geometries that can be manufactured to meet cost, size, shape, and stiffness criteria. Topology optimization is a numerical analysis technique that allows engineers to modify systems and structures using FEA (Finite Element Analysis) software. FEA software such as LS-DYNA, ANSYS, Solidworks, and NX has the capability to set boundary conditions and constraints to mimic realistic impacts. Automotive crashes can be simulated, saving time and cost, allowing the development of enhanced automotive structures computationally. Topology optimization analyzes the data from an impact and optimally distributes materials within a set design domain, dependent on the optimization objective. Additive manufacturing, such as 3D printing, is used to create prototypes of structures and mechanically test the computational simulation. Automotive parts can be created and tested at a fraction of the cost with various design options.

This thesis utilized topology optimization to optimize a front sub-frame to meet mass criteria while increasing the stiffness and durability of the structure. The original and optimized structures were 3D printed and subjected to the simplified load test. The dynamic response of the optimized structure was analyzed and compared to the original for design validation.

Index Terms: Additive manufacturing, automotive structure design, design optimization, dynamic response, finite element analysis (FEA), impact testing, prototype validation, structural stiffness and durability, topology optimization.

Committee Chair/Advisor

Jianren Zhou

Committee Co-Chair

Jaejong Park

Committee Member

Ziaul Huque

Committee Member

April Lovelady

Publisher

Prairie View A&M University

Rights

Date of Digitization

3/27/2026

Contributing Institution

John B Coleman Library

City of Publication

Prairie View

MIME Type

Application/PDF

Recommended Citation

Floyd, D. (2022). The Use Of Topology Optimization In Enhancing Structural Property Of An Automotive Front Sub-Frame. Retrieved from https://digitalcommons.pvamu.edu/pvamu-theses/1669