Design of Automotive Road Racing Rim with Aid of Topology Optimization

A goal of the project was done to develop a new good-looking racing rim of a sports car which would be lighter than existing ones. To achieve the goal, lightweight magnesium alloy Mg ZK60-T5 was applied for the rim, and its preliminary shape was developed employing topology op-timisation. The rim was designed for forging technology; this means that it had to have all manu-facturing features required by that production process.
Based on a literature review, loads, boundary conditions and structural requirements were established, which are crucial for a further development process.
The initial design was created using the topology optimisation, and then a parametric model was developed using a CAD system. As a next step, the first part of validation was done employing FEA in order to meet strength and stiffness targets; some modifications of the CAD model were imposed. As the last step, the final validation was done employing simply fatigue assessment. The optimisation and FEA were completed using Hyperworks 14/ Inspire 2015 software and the CAD model employing Autodesk Inventor 2015.
The results show that the rim design meets theoretically all structural requirements and a good-looking shape was reached. The total mass of 7.9 kg of the designed rim is obtained, which means a reduction about 1.8 kg with the comparison with a reference rim. The 3D model and a technical drawing are completed; this means that the rim can be sent to a production phase.
The results of the project also show that the topology optimisation technology provided by Hyperworks and the advanced CAD system can be used to generate competitive designs with any design offices without difficulties.