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

Year 2025, Volume: 9 Issue: 4, 536 - 546, 31.12.2025

Hamit Sandalcılar , Fatih Çağırankaya , Murat Arslanoğlu , Burak Dikici

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

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

BESO , Fatigue life , Finite element analysis , Formula student , Topology optimization , Weight reduction , upright design

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