Topology optimization-based lightweight design of a certain tubular beam subframe

The design of a tube-beam front subframe was optimized to meet performance and lightweight requirements. Firstly, a 3D mesh model of the subframe was established using HyperMesh software, and the optimization space was determined through sensitivity analysis. Then, the topology optimization was conducted using Optistruct analysis software to determine the layout of the subframe and the optimal position of the cross member. By comparing the performance of the subframe before and after conducting topology optimization under various working conditions, it was observed that the static stiffness at the most critical points of the optimized subframe was significantly improved. Additionally, the strength and modal characteristics were enhanced. Finally, the optimized scheme was verified through bench tests with high accuracy and feasibility, providing a valuable reference for future tube-and-beam subframe design.