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

This project introduces a step‑by‑step structural‑optimization method for the upright of a Formula Student car. The goal is to cut weight dramatically while keeping the part strong enough to handle multi‑axis dynamic loads. First, a CAD model of the upright is built. Realistic loads—braking, cornering, and acceleration forces—are calculated from vehicle‑dynamics equations and applied to the model. Next, finite‑element analysis (FEA) is run in ANSYS Workbench. The analysis checks the initial stress and deformation of the upright made from 7075‑T6 aluminum alloy. A Bidirectional Evolutionary Structural Optimization (BESO) algorithm then reshapes the part. It removes and adds material inside a defined design space, aiming for mass‑retention targets between 30 %

and 70 % of the original weight. To keep the numerical results stable and accurate, mesh‑sensitivity studies and convergence checks are built into the optimization loop. After the optimization, the new design is validated with static structural analysis and a fatigue‑life assessment. These checks confirm that the lightweight upright still meets required safety factors and durability standards. Overall, the framework gives clear guidance for applying advanced topology‑optimization techniques to high‑performance automotive components.

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