Weight Reduction of Rear Wheel Bracket in FSAE Electric Vehicles Using Topology Optimization

Muhamad Hanhan Nugraha (Mechanical Engineering Study Program, Department of Mechanical Engineering, Politeknik Negeri Jakarta)
Muslimin Muslimin (Applied Master of Manufacturing Technology Engineering, Department of Mechanical Engineering, Politeknik Negeri Jakarta)
Anes Inda Rabbika (Mechanical Engineering Study Program, Faculty of Engineering, Universitas Muhammadiyah Tasikmalaya)
Andy Permana Rusdja (Manufacturing Technology Engineering Study Program, Department of Mechanical Engineering, Politeknik Negeri Jakarta)
Rezia Asmiati Syifa (Environmental Engineering, Postgraduate, Institut Teknologi Sepuluh Nopember)
Dian Sahril Anwar (Master of Educational Administration Program, Faculty of Teacher Training and Education, Universitas Galuh)

SINTEK JURNAL: Jurnal Ilmiah Teknik Mesin
Vol. 19 No. 1 (2025): SINTEK JURNAL

This research focuses on reducing the weight of the rear wheel bracket in an FSAE electric vehicle prototype using topology optimization. Lightweight vehicle design is critical for improving energy efficiency and reducing environmental impact. The study aims to optimize the bracket's weight while maintaining structural integrity through a systematic approach. The process began with converting the physical bracket into a digital model using precise measurement techniques and SolidWorks software. Finite element analysis was then conducted to evaluate stress distribution under a working force of 5000 N, assuming Aluminium 6061 as the material. Topology optimization was performed to identify and remove low-stress regions, resulting in a 50% weight reduction from 1.2 kg to 0.63 kg without compromising safety. These findings demonstrate the potential of topology optimization to achieve significant weight reductions in electric vehicle components, thereby enhancing battery efficiency and vehicle range. This approach provides valuable insights for the automotive industry in developing more sustainable and efficient designs.