Dynamic Load FEA Analysis and Optimization of Integrated Steering Knuckle

IPASJ International Journal of Mechanical Engineering (IIJME)
Web Site: http://www.ipasj.org/IIJME/IIJME.htm

Email:editoriijit@ipasj.org
ISSN 2321-6441
A Publisher for Research Motivation ........
Volume 4, Issue 10, October 2016
Dynamic Load FEA Analysis And optimization of

integrated steering knuckle
Ravikant Bawane1, Prof.A.Z.Patel2 ,Prof. A.B.Ghalke3
1
P.G Student, M.E Design Engineering, COE Osmanabad, Maharashtra, India.
Associate Professor, Mechanical Engineering Department, P.G coordinator, COE Osmanabad, Maharashtra, India.
3
Associate Professor, Mechanical Engineering Department, H.O.D, COE Osmanabad, Maharashtra, India.
ABSTRACT
The objective of this project is to reduce the weight of the steering knuckle without compromising the strength of steering
knuckle. Steering knuckle is one of important component of vehicle which is connected to steering, suspension and brake to
chassis of vehicle. It undergoes different loading under different conditions. There has been a strong trend towards the
adoption of optimum materials and components in automotive industry. Conventional steering knuckles comprise an assembly
of two or more forged components that are secured together.In this project the integrated steering knuckle is used. The flanged
body, wheel spindle, tie rod arm and brake caliper bracket are all formed from a single steel billet as a one-piece heavy duty
forging. Such a design eliminates the brake caliper/knuckle joint and the tie rod arm/knuckle joint, and thus, it results in
savings in assembly time and weight.Afinite element software,Hyperworks which contains several modules, is used to achieve
this objective.
Keywords:- Shape Optimization,Steering Knuckle Component
1.INTRODUCTION
Steering knuckle is a prominent component in car which actually takes the loads from the wheels and transfers these
forces to the suspension system. Steering knuckle is main important part in the vehicle because that requires lots of
attention in selection because once it is damaged then it have to replace with the new one. Structural Components such
as a steering knuckle might be strong enough to withstand a single applied load but has a chance to fail when subjected
to a fatigue load.
Optimization methods are developed for manufacturing lighter vehicle. Optimization can be defined as the automatic
process to make a system or component as good as possible based on an objective function and subject to certain design
constraints. There are many different methods or algorithms that can be used to optimize a structure, on OptiStruct is
implemented some algorithms based on Gradient Method.
Mass or weight reduction is becoming important issue in car manufacturing industry. Weight reduction will give
substantial impact to fuel efficiency, efforts to reduce emissions and therefore, save environment. Weight can be
reduced through several types of technological improvements, such as advances in materials, design and analysis
methods, fabrication processes and optimization techniques, etc.
2.LITERATURE REVIEWS
Mahesh P. Sharma [1] has studied static analysis of steering knuckle is carried out. Design a knuckle which
accommodates dual caliper mountings for increasing braking efficiency & reducing a stopping distance of a vehicle.
CAD modal of knuckle was prepared in CREO2.0. Static analysis was done in ANSYS WORKBENCH by constraining
the knuckle, applying loads of braking torque on caliper mounting, longitudinal reaction due to traction, vertical
reaction due to vehicle weight and steering reaction. Also, reducing the weight of vehicle component plays vital role in
increasing efficiency of vehicle and reducing fuel consumption.
The study also illustrates the shape optimization of same knuckle and saved material resource. Shape optimization of
knuckle was done using ANSYS WORKBENCH making objective function as reducing weight. These FEA results are
verified by comparing with analytical calculations. Considering these results modal is modified.
Page 24


ISSN 2321-6441
Purushottam Dumbreet al.[2] have studiedthe weight of the vehicle is going on increasing due to additional luxurious
and safety features. The increasing weight of the vehicle affects the fuel efficiency and overall performance of the
vehicle. Therefore the weight reduction of the vehicle is the real need of todays automotive industry. Steering knuckle
is one of critical component of vehicle. It links suspension, steering system, wheel hub and brake to the chassis. There
is scope to reduce the un sprung weight vehicle. Steering Knuckle is a non-standard part and subjected to various loads
at different conditions. Weight reduction of steering knuckle is the objective of this exercise for optimization. Typically,
the finite element software like OptiStruct (Hyper Works) is utilized to achieve this purpose. For optimization, Nastran
/ Ansys / Abaqus could also be utilized. The targeted weight or mass reduction for this exercise is about 5% without
compromising on the structural strength.
Viraj Rajendra Kulkarni [3] This paper focuses on optimization of steering knuckle targeting reducing weight as
objective function, while not compromising with required strength, frequency and stiffness. Taking into consideration
static and dynamic load conditions, structural analysis and modal analysis were performed. Finite element model was
developed in Hyper-Works. 10 node tetrahedral elements were used for meshing, providing better results in less time.
On constraining the knuckle, combined load of brake torque on the caliper mounting, longitudinal loads due to traction,
vertical reactions due to weight and steering reaction, the finite element model was solved using RADIOSS solver. The
stress levels and deformation was checked using Hyper-View for static as well as dynamic conditions.
Wan Mansor Wan Muhamad [4] The study emphasizes about the effect on fuel efficiency by the reduction in the
mass of the steering knuckle. The shape optimization technique is used to achieve this. Hyperworks was used to achieve
this results. The finite element model was prepared using hypermesh and the analysis is done using Optistruct software.
The static analysis is carried out by applying dynamic loading conditions and optimization was done using shape
Optimization method is used.
3. Methodology
As the prominent part of steering system, the steering knuckle helps in good steering capabilities and optimization of
the same reduces weight and in turn cost.The topology optimization of steering knuckle can make it perform well as
compared to conventional model. The study is performed to reduce weight &increase overall efficiency & improve
strength.The Redesign of steering knuckle is to verify by using customize package of RADIOSS, HYPERMESH to
perform finite element analysis. The static stress analysis is performed and the results are compared with experimental
results.The experimental analysis is to perform on redesign of steering knuckle and the results are obtained to find its
performance. And optimization should be done in Optistruct solver.
Fig 1- Loop of topology optimization
Page 25

ISSN 2321-6441

4.Finite Element Model
The finite element model for knuckle is shown in fig.
Fig.2 Finite Element Model of knuckle

Table1 Material properties
Youngs modulus
205 GPa
Poissons ratio
0.29
Density
7.87
tone/mm^3
Ultimate
stress
Yield stress
Tensile
E-09
440 MPa
370 MPa
5.Model Boundary Condition
Fig.3 Loading conditions on integrated steering knuckle
Page 26

ISSN 2321-6441
The boundary conditions are shown in figure.The boundary conditions are lateral force(13.8KN),vertical force (20.7
KN) and longitudinal or braking force (10.4 KN) applied at the hub.
The model is solved in ANSYS, The plots obtained are as follows
Deformation plot
Stress plot
The maximum deformation is found to be 0.450mm which is very less and The max stress obtained are 247MPa which
means the design is safe.
6.OPTIMIZATION OF STEERING KNUCKLE

Optimization methods were developed to have lighter, less cost and may have better strength too. Many optimization
types, methods, software technique and tools are available due to the revolution of the high speed computing and
software development.
Existing Model
Iteration_1 -Material removal from the longer arm (one side).
Page 27


ISSN 2321-6441
Meshed model and boundary condition application
Max deformation is found to be 0.4503mm

Iteration 2
Material removal from the longer arm (other side)
Max stress is found to be 247MPa
Iteration 3
Page 28

Material removal from the two smaller arm.

ISSN 2321-6441
Iteration 4
Material removal from the circular portion of hub.
Max deformation is found to be 0.505
Max stress is found to be 274MPa

Further optimization leads to stress value near to the yield limit.So, its better to stop at iteration 4.
7.Experimentation
The experimental investigation is performed on fabricated prototype on universal testing machine. The prototype is 1.7
times less than original mass. Due to this vertical force 20.68 KN is change in to 12.15 KN and breaking force is
change to 6.1 KN.The weight of the model is taken from last iteration and then fabricate the model.The deformations
obtained from experimentation is then compare with FEA.
At 10.4KN force(Breaking force) applied the deformation is found to be 0.39 mm.
At 12160N force(Vertical force) applied the deformation is found to be 0.46 mm
Page 29


ISSN 2321-6441
8.Results and discussion

Existing model FEA results for Breaking Force
Deformation is 0.42 mm
Percentage Error =(FEA results - Experimental results)/ FEA results
= (0.42-0.39)/0.42= 7.1 %
Existing model FEA results for Vertical force(20.68 KN)
Deformation is 0.50mm
Percentage Error =(FEA results - Experimental results)/ FEA results
= (0.50-0.46)/0.50= 8.00%
Typically, depending on the type of test and the application, an error margin of about 5 to10% could be considered
close towards validating the proposed design.
Table 2- Comparision of 3 forces with their deformation inFEA and in experimentation
LOAD
Breaking force
Vertical Force
DEFORMATION IN
FEA
0.42 mm
0.505 mm
DEFORMATION IN
EXPERIMETATION
0.39
0.46
% ERROR
7.1 %
8.00 %
Page 30

ISSN 2321-6441

9.Reduction
Table 3-Weight Reduction

Optimization iterations
Weight(Kg)
Existing
23.80
Optimization_1
23.48
Optimization _2
23.02
Optimization _3
22.98
Optimization _4
22.91
Percentage Reduction = (Existing Optimized)/ Existing = (23.80 22.91)/ 23.80

= 3.73 %
10.Conclusion
Weight reduction of 3.73 % is obtained without compromising the strength of steering knuckle.Critical yield strength
of the material is 390MPa, from the result table we conclude that steering knuckle with different iterations are below
critical limit and hence they are safe in design.The iterations are carried out through the optimization process and the
best optimized steering knuckle is chosen for fabrication and testing purpose.The FEA results are compared with the
experimental results with a percentage error of approximately 8%. Which shows a close convergence towards the
results is achieved.
References
[1]. Mahesh P. Sharma, Denish S. Mevawala, Harsh Joshi, Devendra A. Patel, Static Analysis of Steering Knuckle
and Its Shape Optimization, IOSR Journal of Mechanical and Civil Engineering (IOSR-JMCE).
[2]. Purushottam Dumbre, A.K. Mishra, V.S.Aher Structural Analysis of Steering Knuckle for Weight Optimization,
IOSR Journal of Mechanical Engineering (IOSR-JMCE).
[3]. VirajRajendraKulkarni, AmeyGangaramTambe, Optimization and Finite Element Analysis of Steering Knuckle,
Altair Technology Conference, Dec 2013.
[4]. Wan Mansor Wan Muhamad, EndraSujatmika, Hisham Hamid, &FarisTarlochan, Design Improvement of
Steering Knuckle Component Using Shape Optimization, International Journal of Advanced Computer Science,
Feb. 2012.
[5]. MehrdadZoroufi and Ali Fatemi, Fatigue Life Comparisons of Competing Manufacturing Processes: A Study of
Steering Knuckle, The University of Toledo. SAE International
[6]. Kamlesh Chavan, S R Deodas ,S.S. Kulkarni, Mass Reduction for Steering Arm in a Suspension System through
Topology Optimization in CAE(IJSRMS) Journal of Mechanical Engineering Volume 1 Pg:363-371
[7]. Chang Yong Songa, Jongsoo Lee, Reliability based design optimization of knuckle component using conservative
method of moving least square meta-models., Science Direct, 2010.
[8]. B.Babu,M.Prabhu,P.Dharmaraj, R.Sampath, Stress Analysis of Steering Knuckle of Automobile Steering
System, International Journal of Research in Engineering and Technology, March 2014.
[9]. Patel Akash A.Fatigue or Durability Analysis of Steering Knuckle, IJSRD Journal of Mechanical Engineering.
[10]. Sharad Kumar Chandrakar, DheerajLalSoni and ShohelGardia, FEA of A Steering Knuckle for Life Prediction,
International Journal of Engineering Research and Technology.
Page 31

Dynamic Load FEA Analysis and Optimization of Integrated Steering Knuckle

Hochgeladen von

Dokumentinformationen

Originaltitel

Copyright

Verfügbare Formate

Dieses Dokument teilen

Dokument teilen oder einbetten

Freigabeoptionen

Stufen Sie dieses Dokument als nützlich ein?

Sind diese Inhalte unangemessen?

Copyright:

Verfügbare Formate

Dynamic Load FEA Analysis and Optimization of Integrated Steering Knuckle

Hochgeladen von

Copyright:

Verfügbare Formate

IPASJ International Journal of Mechanical Engineering (IIJME)

Web Site: http://www.ipasj.org/IIJME/IIJME.htm

A Publisher for Research Motivation ........

Volume 4, Issue 10, October 2016