Análise estrutural e otimização topológica de uma manga de eixo automotiva

Abstract

This study explores the potential to reduce the mass of the first-generation Chevrolet Onix steering knuckle without compromising its structural integrity by combining Finite Element Method (FEM) analysis with topology optimization. Loading conditions were derived from a vehicle-dynamics study that accounted for forces from the braking and steering systems, as well as vehicle mass and longitudinal and lateral accelerations. The knuckle’s original geometry was captured with an EinScan HX 3D scanner and refined in SolidWorks to generate a high-fidelity solid model, which was then imported into Ansys. Based on these data, an initial static analysis established the baseline structural behavior, after which a topology-optimization algorithm in Ansys produced a lighter geometric configuration that preserves mechanical strength and stiffness requirements, thereby contributing to improved vehicle efficiency.