Meeting the stringent requirements on fuel economy and emissions is still a challenge for automotive original equipment manufacturers (OEMs). In this study, we consider the light weighting opportunities of a heavy commercial truck by evaluating the various requirements of its anti-roll bar. First, an MSC.ADAMS model of the truck is analyzed under some standard vehicle dynamics maneuvers and a target for the anti-roll bar is set. A topology optimization study is then performed using Solid Isotropic Material with Penalization (SIMP) method to determine its dimensions and material to meet this target. For this purpose, a finite element (FE) model of the anti-roll bar is developed in order to determine its torsional stiffness using MSC.Nastran commercial software. The advantages and disadvantages of various optimization results are discussed. Finally, fatigue performance of the anti-roll bar is assessed under the road load data coming from various road simulations. The results prove that the simulation tools and optimization methods offer great capabilities to meet challenging requirements of automotive industry.

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