Topology Optimization of a Bell Crank Lever Based on Stiffness and Mass using Finite Element Analysis

Abstract

The following paper represents the topology optimization of a bell crank lever used in trucks. Current trends indicate a steep rise in the use of topology optimization in all fields. There arises a need for such optimized parts in the automotive industry to increase the overall efficiency of any vehicle. The aim of the present research is to optimization of a bell crank lever arm made of AISI A514 Steel used in trucks and maximizes its performance based on criteria of stiffness and mass. Initially, the model is subjected to loading conditions in accordance with a worst-case scenario and optimized accordingly. The optimized and existing bell crank lever is subjected to static analysis using FEA. Results show a 22 % mass reduction of the crank (3395.71 grams to 2641.02 grams) and a 40% stiffness increase (389.32N/mm to 644.988N/mm) which suits the purpose of the study.

Keywords

• bell crank lever (bcl)
• finite element analysis (fea)
• stiffness
• topology optimization
• von mises stress