Numerical Simulation of Knuckle Joint Using Finite Element Method: A New Approach Based On Composite

IDL - International Digital Library Of
Technology & Research

Volume 1, Issue 5, May 2017 Available at: www.dbpublications.org
International e-Journal For Technology And Research-2017
Numerical Simulation of Knuckle Joint

Using Finite Element Method: A New
Approach Based on Composite
VIVEK SHAW 1, TANUJ SRIVASTAVA2,ROHIT GHOSH3,
DR. RABINDRA NATH BARMAN 4
Department of Mechanical Engineering
1, 3
B.Tech Student, National Institute of Technology, Durgapur; West Bengal, 713209, India
2
M. Tech Student, National Institute of Technology, Durgapur; West Bengal, 713209, India
4
Assistant Professor, National Institute of Technology, Durgapur; West Bengal, 713209, India
Abstract:For the past few decades, there has finite element analysis of the same with
been a rapidprogress in the field ofmaterial science the conventional and composites materials
which has resulted in the reduction of cost and respectively. Composite analysis is based on Rule
weight of materials. This modified systems of mixtures.
developed by incorporating various advanced and
Keywords:Knuckle Joint, CATIA V5R18,
smarter materialshas led to areduction in number of
ANSYS 16.2, FEM, Carbon FiberAluminum.
accidents andtherefore, the safety has increased,
which again has been an utmost concern for any 1. INTRODUCTION
industry in modern times.
The present work is an attempt to provide
Knuckle Joint is a mechanical part which is used to
the readers with a comparative overview in the
connect two rods under tensile load when there is a
context of conventional and advanced materials
requirement of asmall amount of flexibility, or
focusing on a mechanical joint, i.e. the Knuckle
angular moment is necessary. The line of action of
joint. A Knuckle joint finds its extensive
theload is always axial or linear [1]. The axes of
application for connecting two rods subjected to
these two rods either coincide or intersect and lie in
normal tensile load and requiring flexibility in its
one plane. A knuckle joint is unsuitable to connect
angular movements. Here, we are suggesting a
two rotating shafts, which transmit torque [2].
modification over theconventionally used material,
Knuckle Joint is named so because it is free to
such as Aluminium alloythat is widely used for
rotate about the axis of a knuckle pin.A typical
manufacturing the Knuckle joints.The results
knuckle joint has the following parts namely [3].
obtained from our study approves that the use of
composite material not only decreases the weight
1) Fork end
of the material but it also improves the life of the
2) Eye end
component as the composite material shows less
3) Knuckle pin
deformation in comparison to the conventional one.
4) Collar
In the present work, CATIA V5R18 has been used
5) Taper pin
for modellingthe 3D geometry of Knuckle Joint
and ANSYS (Workbench 16.2) is been used for
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Fork end, eye end, and collar are provided with Dimensions of the Knuckle Joint is shown in Table
coaxial holes. Knuckle pin hold the fork end and 1.
the eye end together in a position. The knuckle pin
is held in its position with the help of a collar and a Table 1: Shows the dimensions of different parts of
taper pin. These joint are used for different types of Knuckle Joint
connections, e.g. tie rods, tension links in thebridge
structure [4]. A Knuckle joint can easily be
disengaged when required. Knuckle Joint is Part Dimension
designed and used in different type of equipment Diameter of rod (d) 36 mm
for transmitting load. Some researchers have Diameter of pin (d1) 36 mm
worked on the optimization of steering knuckle Outer Diameter of eye 72 mm
which targets on the reduction of weight as the (d2)
objective function without compromising in terms Diameter of Knuckle 54 mm
of strength, frequency, and stiffness. The Knuckle pin head and collar (d)
worked on undergoes varying load under different Thickness of Single eye 45 mm
condition but it was modeled such that it does not or rod end (t)
affect the steering performance of the vehicle. The Thickness of Fork (t1) 27 mm
work was done in HyperWorks and solved in Thickness of Pin head 18 mm
RADIOSS solver [5][6]. Purushottam Dumbre et (t2)
al.[7] performed their study with the aim to reduce
the weight of knuckle joint and performed finite
element analysis using OptiStruct (Hyper works). The axial load applied P = 70000 N
As weight also becomes an important aspect in the
field of racing industry as it affects the transmission We know, the allowable stress for the rod material
efficiency of the device. Knuckle Joints used for [2].
steering in racing cars are also analyzed and σt = (Ultimate tensile stress/ Factor of safety) =
optimized in accordance with the weight. Nishant 280/2 = 140 Mpa
Vibhav Sexena et al. [8] performed the study and We know, the allowable shear stress for the rod
analysis on Knuckle Joint with the replacement of material [2].
the actual material. They worked on the τ= (shear strength/ Factor of safety) = (207/2) =
maximisation of safety, making the system simple 103.5 Mpa
and eco-friendly. It was seen that the production of Failure of solid rod in tension [2]
the Joint become economical but the strength got π
𝑃 = ∗ 𝑑2 ∗ σ𝑡
reduced to some extent. Another study shows a 4
model which has been drawn in CATIA [9] σt = 68.77 Mpa
Koszalkaet et al. [10] used FEM for the frame Failure of eye end in tension [2]
analysis of a low loader truck. In this study 𝑃 = 𝑑2 − 𝑑1 ∗ 𝑡 ∗ σ𝑡
composite material is applied using rule of mixture. σt = 43.2 Mpa
Similar kind of study using has been done by Rohit
Ghosh et al.[11]. The performed their study on leaf Properties of carbon fibre with aluminium is found
spring model where carbon fibre steel composite is by rule of mixing.
applied on 8th and 9th laminated plate. Young’s modulus Ec=EmVm+EfVf
Ec= 0.4*69000+0.6*300000=207600 Mpa
Density ρc=ρmVm+ρfVf
2. ANALYTICAL ρ c= 0.4 *2700+0.6*1800= 2160 kg/m3
CALCULATION Poisson’s ratio µc=µmVm+µfVf
µc= 0.4*0.334+0.6*0.28= 0.3016


Longitudinal tensile strength S11=SmVm+SfVm
S11= 0.4* 280+ 0.6* 600= 472 MPa
3. MATERIAL PROPERTIES
In the present study, the materials used for
comparative study are Aluminum alloy and Carbon
Fiber with Aluminum composite with volume
fraction of 60:40 and final properties of composite
Fig. 1.Design of Knuckle Joint in CATIA
are obtained by using rule of mixing. The Material
properties used for finite elemental analysis for 4.2 MESHING
both the material are shown in Table 3 [12].
Meshing is done so that at each and every cell the
equation are solved.Meshing improves the quality
Table 3. Material Properties of the solution along with giving higher accuracy to
the solution. [8]The modelled geometry isimported
Material Aluminum Carbon Fiber in ANSYS 16.2 Static Structural workbench for
Properties alloy with meshing. Meshing is done on Proximity and
Aluminum Curvature. Details of mesh is shown in Table
composite 2.Table 2: Details about the meshing for Knuckle
Density(kg/m3) 2770 2160 joint model.
Young’s
71000 207600 Min Size 0.0250190 mm
Modulus(MPa)
Poisson`s Ratio 0.33 0.3016 Proximity Min Size 0.0250190 mm
Tensile yield Max. Face size 25.0190 mm
280 472 Growth size 1.850
strength (Mpa)
Max. size 50.0390 mm
Nodes 165134
4. COMPUTATIONAL Elements 105538
MODELING
4.1 GEOMETRY
The design being studied is knuckle joint which is

modelled in CATIA V5R18 as shown in Fig. 1.In
the design, the joints are boltedand the fork end is
joined with the eye end with the help of knuckle
pin as it acts as a bolt. The knuckle pin is secured
between the two eyes by a tapper pin and collar. Fig. 2. Mesh for Knuckle Joint
4.3 BOUNDARY CONDITIONS

Knuckle pin, taper pin and collar is defined as fixed
support. An axial load of 70 kN is applied at the
end of the joint. Figure --- shows the boundary
condition applied.

Figure 4(a) Distribution of Equivalent stress for

Aluminium alloy
Fig. 3. Boundary condition and load of 70 kN.
5. RESULTS&
DISCUSSIONS Directional
deformatio
5.1 Maximum equivalent (Von-Mises) stress: Figure 5(b) Distribution of Equivalent stress for
n-
Composite application
ANSYS
Figure 4(b) Distribution of Equivalent stress for
Composite application software has a unique module which enables to
measure the amount of deformation i.e. change in
length of the joints. It can be seen that maximum
deformation is experienced at the end of the joints.
From the numerical simulation analysis, the The above results shows that the maximum
maximum equivalent stress was found to be 83.56 displacement at the end of the joints is around
MPa which is less than the allowable stress 0.096669 mm in case when aluminium alloy is
considering factor of safety 2.The ANSYS analysis used. With the introduction of composite material
indicated the maximum stress experiences at the there is noteworthy reduction in the value of
interface between the pin, eye-end and the fork end. maximum directional deformation of 0.025417
The structure therefore has a safety factor of almost mm. The analysis shows that the deformations
2 for this loading and failure mode. The structure is experienced by the components are less when
therefore satisfactory for carrying the axial load of composite material is applied and can be used
70kN. With the introduction of Carbon-fibre safely for the application even for longer time
aluminium for the analysis, there is insignificant duration as compared to when aluminium alloy is
change in equivalent stress occurred. Figure 4 (a used. Figure 5 (a and b) shows the distribution of
and b) shows the distribution of equivalent stress. directional deformation.


64 %
CONCLUSION AND FUTURE

SCOPE
The FEM analysis is done for the knuckle joint. To
analyse the stress, mesh was developed for the
knuckle joint. Due to application of composite
material there has been a negligible change in stress
Fig. 5(a) Distribution of Directional Deformation
value but directional deformation and weight of the
for Aluminium alloy
system got reduced by 73.7 % and 22.02%
respectively. Though the cost of production of
Knuckle Joint with the composite material is
relatively high but the result shows significantly
low deformation. So, with the use of composite
material in, the life of the Knuckle jointincreases.
Also, the weight of the Knuckle Joint decreases.
Thus, Knuckle Joint with this composite material
can be used in places which require replacement of
Weight reduction- tool in large interval of time. Further study can be
carried out in this regard in order to obtain more
Apart from the other benefits, the biggest benefit, accurate results by performing the above analysis
however, is mass reduction for using composite in the ANSYS Composite domain.
materials. The mass of the system when aluminum
alloy is used was 6.215 kg. When composite REFERENCES
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Numerical Simulation of Knuckle Joint Using Finite Element Method: A New Approach Based On Composite

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International e-Journal For Technology And Research-2017