Automotive Structural Engineering
Formula Student Race Car Frame Design Optimization
Re-designed race car frame to eliminate CAD issues.
Performed Linear Static Analysis of the race car frame to ensure structural performance in bending, torsion, and shear loads.
Optimized the frame cross-section using Discrete Size Optimization (OptiStruct) and achieved mass savings of 13.54%.
Brake Pedal Topology Optimization
Meshed the pedal geometry with Hexagonal mesh and performed Linear Static Analysis for pressure loading.
Reduced the pedal mass by 12.7% using topology optimization with manufacturing constraints (forging).
Designed the optimized brake pedal on Siemens NX.
Car Fender Design
Designed a fender for an SUV using Siemens NX and selected Carbon Fibers – Continuous Fiber Reinforced Vinyl Ester and injection molding as a manufacturing process to ensure low cost and weight and meet all fender design requirements.
Analyzed the effect of changes in the mechanical behavior with changes in fiber orientation, fiber volume fraction, and porosity during the injection molding process.
Torque Control Arm
Optimized the torque control arm to increase its fatigue life by changing its geometry.
Achieved a mass saving of 17.44% and the target fatigue life of 20000 loading cycles using Free-Shape Optimization (OptiStruct).
S-Rail Component
Performed size and shape optimization on a structural rail to prevent buckling.
Met the buckling requirements with the design volume constraint using Size and Shape Optimization (OptiStruct).
Rib-Reinforced Plate
Optimized the shape of the plate reinforcements to minimize nodal displacement of the plate subjected to modal excitation.
Met the design constraint of light-weighting (mass less than 2 kg) using Shape Optimization (OptiStruct).
Slider Suspension
Optimized the Slider suspension geometry to increase the stiffness and make it lighter at the same time.
Achieved a mass reduction of 7% using Topology and Topography Optimization (OptiStruct).
Automotive Control Arm
Optimized the control arm design to minimize mass and volume, with displacement constraints for various load cases (braking, cornering, pothole).
Achieved a mass reduction of 8.2% using Topology Optimization (OptiStruct).