Design optimization and analysis of rear

knuckle of ATV to reduce the manufacturing

complexity and to improve strength
Cite as: AIP Conference Proceedings 2283, 020105 (2020); https://doi.org/10.1063/5.0025408
Published Online: 29 October 2020

R. Kishore, S. Sivaraj, K. Karthikeyan, and G. Kathick

AIP Conference Proceedings 2283, 020105 (2020); https://doi.org/10.1063/5.0025408 2283, 020105

© 2020 Author(s).
 Design optimization and analysis of rear knuckle of ATV to
reduce the manufacturing complexity and to improve
strength
R Kishore1, S Sivaraj1, a), K Karthikeyan 1 and G Kathick1
1
Department of Mechanical Engineering, Chennai Institute of Technology, Chennai, Tamil Nadu, India.

a)
Corresponding author:sivarajs@citchennai.net

Abstract. This research deals with the knuckle joint of all-terrain vehicles where the major stresses are imposed on the
vehicles used in mountains and uneven geographical areas the vehicle has to withstand high loads and bumps, considering
the manufacturing difficulties and load distribution criteria this research deals with optimization of design for easier
manufacturing and stability. These joints are utilized to connect two rods where the axes coincide or they have to intersect
and must lie in one plane. These are the major parts where it limits the angular movement between the rods about the axis
of the pin and to transmit the axial force. These rods are constrained to tensile stress and yield stress where the selection of
materials and the pin is been subjected to shear stress and bending stress. It proves strength is the major criteria to select
the pin. The objective of this research is to design and analysis the structural deformations in a Knuckle joint. Here the
Knuckle joint is designed and analyzed using SOLIDWORKS.

INTRODUCTION

A Knuckle joint connects two distinguish rods under the tensile loads. The basic design of a knuckle joint is simple
and it can be easily assembled and disassembled when required. Typical applications of knuckle joints are: links
between suspension lever fulcrum etc. It is not possible to connect two rotating shafts or moving parts which transmit
torque [1,2]. Eye is formed on one of the rods and fork is formed on the other. The Eye which fits inside the fork and
the pin is usually passed through both the fork and the eye. Fasteners connections often play an important part in the
transmission of load through machine assemblies. In huge circuit breakers knuckle are subjected occasionally to high
impulsive loads transmitted through large-scale linkages. The material used for the joint is usually steel or aluminum
[3, 4].

There are four declines for the optimizing procedure:

Topology optimization: This process is used to give minimalized and effective material layout according to the
design and load considerations.
Shape optimization: This process used to derive the optimum fillets according to the design and load
considerations.
Size optimization: This process used to derive optimum process is to obtain the best allowable thickness value
according to load and shape of the component.
Topography: This optimization used to derive best results in which a region of design can be identified and
variation in shape is produced and reinforced.

Proceedings of International Conference on Recent Trends in Mechanical and Materials Engineering

AIP Conf. Proc. 2283, 020105-1–020105-9; https://doi.org/10.1063/5.0025408
Published by AIP Publishing. 978-0-7354-4013-5/$30.00

020105-1
 FIGURE 1. Cad Model of the Existing design

WORK FLOW

As the knuckle plays an important role in the vehicle dynamics the material is selected based on the previous
analysis and research comparisons, the finite element model is been created using the SOLIDWORKS ANALYSIS
software and necessary boundary conditions are prescribed by using solvers a tool which is used in Solid works,
precisely the weight has been reduced to optimize the design and necessary strength and stiffness have been mentioned
in the design for analysis and vibration target has been defined.
When the design is finally optimized after satisfying all the constraints which is given and the load variables which
the vehicle will experience during the life cycle.

ANALYSIS OF THE EXIXTING MODEL:

Volumetric Properties

Mass :0.220853 kg
Volume :8.17973e-05 m^3
Density :2700 kg/m^3
Weight :2.16436 N

FIGURE 2. Ansys model of the Existing design

020105-2
 MATERIAL PROPERTIES

The properties of the materials used in the knuckle of all-terrain vehicle is listed below

TABLE 1. Material Properties of Existing design

S.No PROPERTIES Values

1 NAME 6061-T6 (SS)
2 MODEL TYPE Linear Elastic Isoropic
3 DEFAULT FAILURE Max Von Mises Stress
4 YEILD STRENGTH 2.75e+08 N/m2
5 TENSILE STRENGTH 3.1 e+08 N/m2
6 ELASTIC MODULUS 6.9e+10 N/m2
7 POISON’S RATIO 0.33
8 MASS DENSITY 2700 Kg/ m3
9 SHEAR MODULUS 2.6 e+10 N/m2
10 THERMAL EXPANTION 2.4 e-05/Kelvin

MESH PROPERTIES
TABLE 2. Mesh Properties of Existing design

S.No CRITERIA Values

1 TOTAL NODES 14866

2 TOTAL ELEMENTS 8387

3 MAXIMUM ASPECT RATIO 5.3525

4 % OF ELEMENTS WITH ASPECT RATIO < 3 9.89

5 % OF ELEMENTS WITH ASPECT RATIO >10 0

6 % OF DISORTED ELEMENTS (JACOBIAN) 0

7 TIME TO COMPLETE MESH(hh.mm.ss) 00.00.02

020105-3
 FIGURE 3. Mesh model of the Existing design

RESULTANT FORCES

Reaction forces
TABLE 3. Reaction forces of Existing design

SELECTION SET Entire model

UNITS Newton

SUM X 6.78008e-05

SUM Y -0.459536

SUM Z -2.83355

RESULTANT 2.87057

Reaction moments

TABLE 4. Reaction moments of Existing design

SELECTION
Entire model
SET
UNITS N.m

SUM X 0

SUM Y 0

SUM Z 0

RESULTANT 0

020105-4
 STUDY RESULTS OF EXISTING MODEL
The analysis model from SOLIDWORKS analysis has been listed below and the considerations taken into account
are Von Mises Stresses, Equivalent Strain and Resultant displacement.

FIGURE 4. Von Mises Stresses of the Existing design

FIGURE 5. Equivalent Strain of the Existing design

020105-5
 FIGURE 6. Resultant Displacement of the Existing design

NEED FOR MODIFIED DESIGN

This design deals with manufacturing reliable as well as durable steering upright for ATV to overcome the existing
failure. The new updated design of the upright is a model of spindle type where the frame and spindle are manufactured
with similar or dissimilar materials. The locknut arrangements is provided at the end of the spindle and to improve the
strength at the same time to restrict the lateral movement of the wheel hub.
The model is verified for the entire sturdiness load that helps for important mass reduction from the model.
Integrated style of producing an approach which supports from the improvisation of structural part. Generally the
suspension mountings are in direct contact with the chassis of the vehicle and they should be constrained.
From the designed model the FEA analysis has to be carried out and the lateral forces were constrained to the
bearing support which is supported at knuckle. The designed cad model of the upright is done in 3D by solid works.
The necessary constraints of caliper mountings stub axle, tie rod mounts, upper and lower mounts, suspension
geometry and steering geometry are the major considerations where knuckle is mainly depends upon.

FIGURE 7. Cad model of the modified design

020105-6
 ANALYSIS OF THE MODIFIED MODEL

The designed upright with the calculated loads and considering the mounting points as well as bearing surfaces.
The material will be considered to be aluminum with 6-series Al6081. The modelling with solid works 3D model is
analyzed foe stress and displacement performed by the upright by involving the design into various loads calculated
in previous selection process.

Volumetric Properties

Mass : 0.712672 kg
Volume : 0.000263953 m^3
Density : 2700 kg/m^3
Weight : 6.98418 N

MESH PROPERTIES
TABLE 5. Mesh Properties of Existing design

S.No CRITERIA Values

1 TOTAL NODES 16388

2 TOTAL ELEMENTS 9354

3 MAXIMUM ASPECT RATIO 6.3225

4 % OF ELEMENTS WITH ASPECT RATIO < 3 7.84

5 % OF ELEMENTS WITH ASPECT RATIO >10 0

6 % OF DISORTED ELEMENTS (JACOBIAN) 0

7 TIME TO COMPLETE MESH(hh.mm.ss) 00.00.02

STUDY RESULTS OF MODIFIED MODEL

The analysis model from SOLIDWORKS analysis has been listed below and the considerations taken into account
are Von Mises Stresses, Equivalent Strain and Resultant displacement.

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FIGURE 8. Resultant Displacement of the Modified design

FIGURE 9. Equivalent Strain of the Modified design

FIGURE 10. Resultant Displacement of the Modified design

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 CONCLUSIONS

It can be concluded that the knuckle which is modified has high strength to weight ratio and it has very important
advantage in manufacturing the manufacturing of earlier design has very tedious process in manufacturing which
includes vertical milling, drilling and usage of CNC machine for precise output.
Comparatively the modified design is very simple in design and it have a very less wastage of material in
manufacturing and the manufacturing process is comparatively simple than the existing model and the strength is also
improved which can be seen in the analysis output.

REFERENCE

1. Prof. R. L. Jhala et. Al (2009) asses fatigue life and compares the fatigue performance of the steering knuckle
made from three materials of different manufacturing performance.
2. Workshop report published by the United States government (Feb 2013) focused on the development of the light
weight vehicles and technology gap and also set a goal for optimizing the weight of the chassis and suspension
system by 25% by the year 2020
3. Society of Automobile engineering report published in the year 2010 by Aditya Bhatt in the name of kinematic
analysis of formula SAE suspension in view of optimizing the steering geometry in the race car.
4. Raj Kumar Roy in year 2008 in the name of focus on the recent approaches to automating the manual
optimization process and the challenges that it presents to the engineering community

020105-9