Structural Optimization of a Formula Student Upright Using the BESO Method: Enhancing Performance Through Lightweight Design

Hamit Sandalcılar; Fatih Çağırankaya; Murat Arslanoğlu; Burak Dikici

doi:10.30939/ijastech..1724606

Structural Optimization of a Formula Student Upright Using the BESO Method: Enhancing Performance Through Lightweight Design

Abstract

This study presents a comprehensive design and optimization approach for the upright component used in Formula Student vehicles, with the primary objective of reducing weight while ensuring structural integrity and manufacturability. The upright, as a critical suspension component, must withstand complex multi-axial loads during braking, cornering, and acceleration. To address these challenges, a combination of advanced engineering tools and methods was utilized. Using SolidWorks for initial CAD modeling and ANSYS Workbench 2023 for finite element analysis (FEA), realistic loading scenarios were simulated based on dynamic vehicle conditions. These included vertical, lateral, and longitudinal forces derived from vehicle dynamics calculations. The mechanical behavior of 7075-T6 aluminum alloy was fully integrated into the simulation environment. A Bidirectional Evolutionary Structural Optimization (BESO) technique was applied to minimize structural mass while preserving stiffness and strength. The topology optimization was carried out within a defined design space, using a mass retention constraint ranging from 30% to 70%. Convergence monitoring and mesh sensitivity analyses ensured accurate and stable optimization outputs. Post-optimization validation included both static structural analysis and fatigue life assessment. The final design demonstrated significant improvements: a 58.75% weight reduction per upright, stress levels well below the material’s yield limit, and fatigue life exceeding 10⁸ cycles, indicating infinite operational life. These results underline the effectiveness of topology optimization, not only in achieving lightweight designs but also in improving dynamic performance, energy efficiency, and manufacturability in high-performance motorsport applications.

Keywords

References

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Details

Primary Language

English

Subjects

Automotive Engineering Materials

Journal Section

Research Article

Authors

Hamit Sandalcılar
0009-0009-3930-5139
Türkiye

Fatih Çağırankaya
0000-0002-3537-1659
Türkiye

Murat Arslanoğlu
0000-0003-2995-9699
Türkiye

Burak Dikici ^*
0000-0002-7249-923X
Türkiye

Publication Date

December 31, 2025

Submission Date

June 23, 2025

Acceptance Date

November 19, 2025

Published in Issue

Year 2025 Volume: 9 Number: 4

DOI

https://doi.org/10.30939/ijastech..1724606

IZ

https://izlik.org/JA45EM27ZN

Cite

RIS / Bibtex

APA

Sandalcılar, H., Çağırankaya, F., Arslanoğlu, M., & Dikici, B. (2025). Structural Optimization of a Formula Student Upright Using the BESO Method: Enhancing Performance Through Lightweight Design. International Journal of Automotive Science And Technology, 9(4), 536-546. https://doi.org/10.30939/ijastech..1724606

AMA

1.Sandalcılar H, Çağırankaya F, Arslanoğlu M, Dikici B. Structural Optimization of a Formula Student Upright Using the BESO Method: Enhancing Performance Through Lightweight Design. IJASTECH. 2025;9(4):536-546. doi:10.30939/ijastech.1724606

Chicago

Sandalcılar, Hamit, Fatih Çağırankaya, Murat Arslanoğlu, and Burak Dikici. 2025. “Structural Optimization of a Formula Student Upright Using the BESO Method: Enhancing Performance Through Lightweight Design”. International Journal of Automotive Science And Technology 9 (4): 536-46. https://doi.org/10.30939/ijastech. 1724606.

EndNote

Sandalcılar H, Çağırankaya F, Arslanoğlu M, Dikici B (December 1, 2025) Structural Optimization of a Formula Student Upright Using the BESO Method: Enhancing Performance Through Lightweight Design. International Journal of Automotive Science And Technology 9 4 536–546.

IEEE

[1]H. Sandalcılar, F. Çağırankaya, M. Arslanoğlu, and B. Dikici, “Structural Optimization of a Formula Student Upright Using the BESO Method: Enhancing Performance Through Lightweight Design”, IJASTECH, vol. 9, no. 4, pp. 536–546, Dec. 2025, doi: 10.30939/ijastech..1724606.

ISNAD

Sandalcılar, Hamit - Çağırankaya, Fatih - Arslanoğlu, Murat - Dikici, Burak. “Structural Optimization of a Formula Student Upright Using the BESO Method: Enhancing Performance Through Lightweight Design”. International Journal of Automotive Science And Technology 9/4 (December 1, 2025): 536-546. https://doi.org/10.30939/ijastech. 1724606.

JAMA

1.Sandalcılar H, Çağırankaya F, Arslanoğlu M, Dikici B. Structural Optimization of a Formula Student Upright Using the BESO Method: Enhancing Performance Through Lightweight Design. IJASTECH. 2025;9:536–546.

MLA

Sandalcılar, Hamit, et al. “Structural Optimization of a Formula Student Upright Using the BESO Method: Enhancing Performance Through Lightweight Design”. International Journal of Automotive Science And Technology, vol. 9, no. 4, Dec. 2025, pp. 536-4, doi:10.30939/ijastech. 1724606.

Vancouver

1.Hamit Sandalcılar, Fatih Çağırankaya, Murat Arslanoğlu, Burak Dikici. Structural Optimization of a Formula Student Upright Using the BESO Method: Enhancing Performance Through Lightweight Design. IJASTECH. 2025 Dec. 1;9(4):536-4. doi:10.30939/ijastech. 1724606