Topological Optimization of an Automotive Steering Column Lever

Current shape optimization methods bring crucial gains with respect to the functions to be optimized. They are widely used by industry, especially in the automotive sector such as the PSA Group. Among these approaches, geometry optimization is limited to a relatively small design volume coupled with functional, weight, and manufacturing cost requirements. In this paper, we aim to reconstruct a CAD model of an automotive steering wheel that is parameterized from a functional surface that meets imposed loading and displacement conditions. We propose an approach to identify the forbidden zones of the design space and manage them in a topological optimization loop. This is to optimize an industrial assembly process that adjusts the aerodynamic drag coefficient of a vehicle. Thus, criteria for weight, stress, plastic strain, and flow uniformity during the injection of a polymer component are selected for decision-making. This innovative method transfers the geometry from a constraint and input factor to an output response to optimize materials, geometries, and manufacturing processes. As a result, a weight reduction of 22.73% is achieved, coupled with a 58.9% improvement in strength and a 66% reduction in induced plastic strain under service loading.