Topology Optimization of the Gearbox Shift Fork Based on the Variable Density Method

The shift fork is a part of the automobile transmission, located at the lower end of the handle by flipping the intermediate transmission wheel so that the input/output speed ratio change is an essential structure in automobile transmission. In this paper, the variable shift fork is taken as the research object, and the finite element model of the shifting fork is established based on ABAQUS. The topology optimization of the shifting fork is carried out to meet the strength and stiffness requirements. The optimization model is analyzed according to the actual engineering conditions. The optimization aims to improve the strength and stiffness of the forks to reduce weight and improve performance. By comparing the mass of the optimized transmission fork before and after the optimization, compared with the original model of 1.20kg, the optimized transmission fork mass of 0.84kg is reduced by 0.35kg, and the weight reduction rate is 29.5%. It is indicated that the optimized transmission fork is lighter, stronger, and more efficient, which can improve the performance and economy of the vehicle. Pre-optimization and post-optimization scenarios were compared to determine the best solution. It can provide helpful information to car manufacturers and designers to optimize the design and performance of vehicle transmissions.