Structural Analysis, Topology Optimization and Comparative Evaluation of an Automotive Lower Control Arm for Weight Reduction

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This study presents the design, finite element analysis and topology optimization of an automotive front lower control arm based on the suspension configuration of the Mahindra Scorpio. A CAD model was developed and evaluated in ANSYS under representative loading conditions including static, full-load, braking, cornering, combined loading and pothole-impact cases. Structural steel, Aluminium 7075-T6 and Ti-6Al-4V were considered during material comparison, after which the analyzed design was evaluated using structural steel. The study examined von Mises stress, total deformation, elastic strain and factor of safety. Topology optimization was then used to remove low-utilization material while retaining the principal load paths, followed by CAD reconstruction and re-analysis under identical conditions. The original model mass was 3.8882 kg, while the optimized model mass was 3.6994 kg, giving a 4.85% reduction. Maximum von Mises stress increased from 235.28 MPa to 249.69 MPa and maximum deformation increased from 0.80285 mm to 0.8588 mm. The optimized model retained a minimum factor of safety of 1.0012. The results demonstrate a measurable weight saving with a moderate structural-performance penalty.