DESIGN AND MANUFACTURING

OF STEERING SYSTEM OF A
FORMULA PROTOTYPE
VEHICLE
Under the guidance of

Prof. D V Khankal
 CONTENTS

• INTRODUCTION
• FUNCTIONS OF STEERING SYSTEM
• COMPONENTS OF STEERING SYSTEM
• STEERING GEOMETRY
• STEERING MECHANISMS
• STEERING COLUMN
 INTRODUCTION
• The basic aim of steering is to ensure that the wheels are
pointing in the desired directions.

• It’s the key interface between the driver and the vehicle.

• The objective is to design the steering system which is a direct

transmission from the steering wheel to the front wheels, is
compliant and works well with all other subsystems.
 FUNCTIONS OF STEERING SYSTEM

• It helps in swinging the wheels to the left or right.

• It helps in turning the vehicle at the will of the driver.
• It helps in achieving the self-rightening effect.
• It converts the rotary movement of the steering wheel into an
angular turn of the front wheels.
• It multiplies the effort of the driver by leverage in order to make
it fairly easy to turn the wheels.
• It absorbs a major part of the road shocks thereby preventing
them to get transmitted to the hands of the driver
COMPONENTS OF STEERING SYSTEM

1. Steering wheel
2. Steering column
3. Rack and pinion
4. Steer arm
5. Upright/ knuckle
 DESIGN STEPS INVOLVED
1. Identification of vehicle requirement
2. Selection of optimum geometry
3. Selection of optimum gearbox mechanism
4. Virtual prototyping
5. Analysis of system using various softwares
STEERING GEOMETRY
• It refers to the angular relationship between
suspension and steering parts, front wheels
and the road surface
• As the alignment deals with angels and
affects steering, the method of describing
alignment measurement is called steering
geometry.
• Basic steering geometry angles
• Camber
• Caster
• Toe
• King pin inclination
TYPES OF STEERING GEOMETRIES

Ackerman Davis
 Ackerman Davis

• Mechanism is in the back of the • Mechanism is in the front of

wheels the wheels
• Consists of a turning so less • Consists of a sliding pair so
friction and wear more friction and wear
• Positions of correct gearing are:
• It is an exact steering gear
when the vehicle moves straight
mechanism and fulfils the
when the vehicle moves a correct
fundamental equation of
angle to the right and left
geering in all positions
in other positions slippage occurs
 STEERING GEARBOX MECHANISMS

• It produces a gear reduction between the input steering wheel and the output
drop arm (Pitman arm)
• It redirects the input to output axis of rotation through a right angle.
• The overall angular gear ratio of a steering gearbox may be as direct as 10:1 to
14:1 for light small vehicles or as indirect as 26:1 to 28:1 for heavy vehicles.
• Types:
1. Worm and Wheel Steering Gear box
2. Worm and Roller Steering Gear box
3. Re-circulating Ball type Steering Gear
4. Rack and Pinion type Steering Gear box
RACK AND PINION

• It turns the rotational motion of the steering

wheel into linear motion required to turn the
wheels

• It provides a gear reduction making it easier

to turn the wheels

• The rack and pinion gear set is enclosed in a

metal/composite material tube with each end
of the rack protruding from the tube.

• A rod called a tie rod connects to each end of

the rack. The steering gear is attached to the
steering column.

• When you turn the steering wheel, the gear

spins, moving the rack. The tie rod at end of
the rack connects to the steering arm on the
upright.
 STEERING COLUMN
• The automotive steering column is a device intended primarily for connecting the
steering wheel to the steering mechanism or transferring the driver's input torque
from the steering wheel. The steering column may consist of either a
i. Universal joint or a
ii. Bevel gear pair.
• Secondary functions:
a. Energy dissipation management in the event of a frontal collision;
b. Provide mounting for: the multi-function switch, column lock, column wiring,
column shroud(s), transmission gear selector, gauges or other instruments as
well as the electro motor and
c. Offer (height and/or length) adjustment to suit driver preference
UNIVERSAL JOINT

• A universal joint is a positive, mechanical

connection between rotating shafts, which
are usually not parallel, but intersecting.
They are used to transmit motion, power,
or both.
 Advantages
• Low side thrust on bearings.
• Large angular displacements are
possible.
• High torsional stiffness.
• High torque capacity.
Disadvantages
• Velocity and acceleration fluctuation
increases with operating angle.
• Lubrication is required to reduce
wear.
• Shafts must lie in precisely the
same plane.
• Backlash difficult to control.
BEVEL GEAR
• Bevel gears are gears where the axes of the
two shafts intersect and the tooth-bearing
faces of the gears themselves are conically
shaped.
• Most often mounted on shafts that are 90
degrees apart, but can be designed to work at
other angles as well.
• The pitch surface of bevel gears is a cone.
• Types
a. Straight bevel gears
b. Spiral bevel gears
 Advantages Disadvantages

• This gear makes it possible to change the • One wheel of such gear is designed
operating angle.
to work with its complementary
• Differing of the number of teeth (effectively wheel and no other.
diameter) on each wheel allows mechanical
advantage to be changed. • Must be precisely mounted.
• By increasing or decreasing the ratio of • The shafts' bearings must be
teeth between the drive and driven wheels
one may change the ratio of rotations
capable of supporting significant
between the two, meaning that the rotational forces.
drive and torque of the second wheel can be
changed in relation to the first.