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An engine bracket is one of the most critical components of the engine used for mounting and supporting the engine in the vehicles. Today, the automobile industry requires lightweight components, which will reduce the car's overall weight when fitted into the vehicle. Topology optimization is a technique with the help of which the surface of a component is optimized to get the required shape for having reduced weight. The weight is reduced by optimizing the material on the surface of the details. In this paper, the work done is the application of topology optimization on the surface of the engine bracket arm. Then the optimized model is tested computationally using realistic conditions. Bi-directional evolutionary structural optimization is used as a technique for topology optimization. With the help of the BESO method, the material optimization is done, and then the weights are compared with the original component. A new algorithm is developed using MATLAB codes. The sensitivity ratio is considered using the von Mises strength as a critical parameter for the BESO method for optimization. The optimized bracket model is then assembled with the hub of the component, and then the assembly is simulated for verification using standard conditions. A comparison of weight reduction is there using topology optimization.

Steering knuckle connects steering system, suspension system and braking system to the chassis. The steering knuckle contributes a significant weight to the total weight of a vehicle. Increasing the efficiency of an automobile without compromising the performances is the major challenge faced by the manufacturers. This paper presents an effective topology optimization of steering knuckle used in a vehicle with the primary objective of minimizing weight. The study on optimization of knuckle is divided into two phases, the first phase involves making of a computer-aided design model of the original steering knuckle and carry out finite element analysis on the knuckle by estimating the loads, which are acting on the component. In the second phase, design optimization of the model of steering knuckle is carried out, and excess material is removed at the region where induced stress is negligible as obtained in finite element analysis assuming standard boundary and loading conditions. The paper describes a research work carried out to optimize structural topology giving the essential details. The methodology may be applied to optimize structural components used in applications where the ratio of desired properties to the cost, generally in terms of weight, is to be optimized. In the case of automobiles, strength to weight ratio has to be maximized. New researchers working in the area will have an understanding of the procedures, and further, the techniques may be applied to design in general.