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Structural Analysis of Steering Knuckle For Weight Reduction
Structural Analysis of Steering Knuckle For Weight Reduction
Website: www.ijetae.com (ISSN 2250-2459, ISO 9001:2008 Certified Journal, Volume 4, Issue 6, June 2014)
552
International Journal of Emerging Technology and Advanced Engineering
Website: www.ijetae.com (ISSN 2250-2459, ISO 9001:2008 Certified Journal, Volume 4, Issue 6, June 2014)
The study identifies scalability as the major challenge for The topology optimization of the component is carried out
design optimization techniques. GAs is the most popular and substantial reduction in weight about 70 kg is obtained
algorithmic optimization approach. Large-scale and also obtained stress and deformation within acceptance
optimization will require more research in topology design, criteria.
computational power and efficient optimization algorithms. 7. Rajeev Sakunthala Rajendran et. al. (2013) discuss the
3. S. Vijayaranganet.al.(2013) uses the different material process of designing a light weight knuckle from scratch.
than regular material for optimization of steering knuckle. The design space is identified for the knuckle and
They use Metal Matrix Composites (MMCs) as it have subsequently a design volume satisfying the packaging
potential to meet demanded design requirements of the requirements is created from it. Using Opti Struct, topology
automotive industry, compared with conventional optimization is performed on the design volume to derive
materials. Structural analysis of steering knuckle made of the optimal load path required for the major load cases.
alternate material Al-10 wt% Tic was performed using Hypermorph is used to create the required shape variable
commercial code ANSYS. It is found from the analysis; the and Hyper Study is used as optimizer. The process of using
knuckle strut region has maximum stress and deflection Topology optimization for load path generation&
during its life time. The results obtained from numerical Parametric study using shape optimization, reduces the
analysis and experimental testing using particulate design iteration and intermediate concept models and there
reinforced MMCs for steering knuckle with a weight by reduces the design cycle time.
saving about 55% when compare with currently used SG There are four disciplines for optimization process:
iron.
Topology optimization: It is an optimization process which
4. Prof.R. L. Jhala et. al. (2009) assesses fatigue life and gives the optimum material layout according to the design
compares fatigue performance of steering knuckles made space and loading case.
from three materials of different manufacturing processes.
Shape optimization: This optimization gives the optimum
These include forged steel, cast aluminum, and cast iron
fillets and the optimum outer dimensions.
knuckles. Finite element models of the steering knuckles
were also analyzed to obtain stress distributions in each Size optimization: The aim of applying this optimization
component. Based on the results of component testing and process is to obtain the optimum thickness of the
finite element analysis, fatigue behaviors of the three component.
materials and manufacturing processes are then compared. Topography: It is an advanced form of shape optimization,
They conclude with that forged steel knuckle exhibits in which a design region is defined and a pattern of shape
superior fatigue behavior, compared to the cast iron and variable will generate the reinforcements.
cast aluminum knuckles.
5. k. h. Chang and P.S. Tang(2001) discuss an integrated III. METHODOLOGY
design and manufacturing approach that supports the shape The normal mode analysis and stiffness of the steering
optimization. The main contribution of the work is knuckle is obtained using finite element analysis. Finite
incorporating manufacturing in the design process, where element modeling is done using HYPERMESH and the
manufacturing cost is considered for design. The design necessary boundary conditions and material are imposed on
problem must be formulated more realistically by it. The setup is solved using RADIOSS solver. Weight
incorporating the manufacturing cost as either the objective reduction is done using optimization software
function or constrain function. OPTISTRUCT. The weight reduction is done using
6. Patel Nirala and Mihir Chauhan(2013) carry out the Topology optimization by meeting the strength, stiffness
topology optimization of clamp cylinder t using CAE tools and vibration targets. And the corresponding weight
to reduce weight with the constraints of standard operating reduction is analyzed. The design direction given by the
condition. The new optimized design of configuration is OPTISTRUCT is used to do the design modifications and
proposed.FEA of optimized cylinder is also carried out and with few iterations, the optimized design satisfying all the
compared with acceptance criterion. The optimized model strength, stiffness, vibration & life-cycle performance
is equally strong and light in weight compared to existing criteria is evolved.
model.
553
International Journal of Emerging Technology and Advanced Engineering
Website: www.ijetae.com (ISSN 2250-2459, ISO 9001:2008 Certified Journal, Volume 4, Issue 6, June 2014)
The design is validated further by performing linear Table 1.
static analysis and normal mode analysis using RADIOSS. Nodes and Elements of model
The complete approach is shown in flow chart. Element C3D10
No. of Element 55689
Nodes 93694
Material M122-HSS180- max
CAD model of steering knuckle was developed in 3D The base geometry is simulated for the actual loading
modeling software CATIA. it consists of stub hole, brake conditions. The load conditions are obtained from data
caliper mounting points, steering tie-rod mounting points, acquisition system. The loadings are as follows.
suspension upper and lower A-arm mounting points.
Knuckle design mainly depends on suspension geometry
and steering geometry.
V. MATERIAL SELECTION
There are several materials used for manufacturing of
steering knuckle such as S.G. iron (ductile iron), white cast
iron and grey cast iron. But grey cast iron mostly used.
Forged steel are most demanding material for this
application. For this Ferrite ductile iron is used
VI. MESHING
CAD model of knuckle converted into STEP file. This
Fig.2.Loading conditions
model is imported into Abaqus Workbench simulation.
Geometry cleanup was performed prior to meshing of
model. Optistruct is used as solver. For better quality of
mesh fine element size is selected.
554
International Journal of Emerging Technology and Advanced Engineering
Website: www.ijetae.com (ISSN 2250-2459, ISO 9001:2008 Certified Journal, Volume 4, Issue 6, June 2014)
555
International Journal of Emerging Technology and Advanced Engineering
Website: www.ijetae.com (ISSN 2250-2459, ISO 9001:2008 Certified Journal, Volume 4, Issue 6, June 2014)
The mass reduction for the front knuckle was found to
be 11%, compared to the currently used model. Optimized
model is shown in fig.7 This result is satisfactory
considering using topology optimization, with limited
design space given and no change in material properties.
Summary of results is shown in Table 2.
Table 2
Summery Of Result
Initial Optimised %
Design Design Reduction
Displacement 0.2 mm 0.21mm
IX. CONCLUSION
556
International Journal of Emerging Technology and Advanced Engineering
Website: www.ijetae.com (ISSN 2250-2459, ISO 9001:2008 Certified Journal, Volume 4, Issue 6, June 2014)
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