Performance, Design, and
250 gram lesser. . .
Design Optimization and Simulation of Steering Knuckle
This project concentrates on design optimization of upright (also called steering knuckle, hub or spindle) mainly to achieve reduced weight with necessary stiffness and strength. By reducing the weight of the component, we are also reducing the inertia load, improving the vehicle’s performance and fuel economy. A steering knuckle of the automotive suspension system is the assembly that includes the wheel hub or spindle and connects to the suspension components. The wheel and tire assembly are attached to the spindle (or hub) of the knuckle where the wheel rotates while being held in a balanced plane of motion by the knuckle/suspension assembly.
The goal is to design a knuckle that has an optimum weight.
Software Used:
CAD Software: NX Siemens (NX 1980)
FEA and Simulation: Simcenter 3D
Solver: Simcenter Nastran - Structural
Solution Type: SOL 200 Topology Optimization
Actual Model of the Upright
CAD Model of the Upright in NX Siemens
Meshed Model of the Upright in Simcenter 3D
Applying Loads and Constraints . . . .
Mass of a vehicle: 1083 kg (Maruti Suzuki Swift)
Weight on single tire = 270.75 kg
Material: S.G. Iron (ductile iron)
Application of Loads on the Upright
Design Optimization:
The application of topological optimization is chosen as a tool to design the shape of the upright, making it lightweight, without compromising its initial performance when compared to the existing design of the upright.
To optimize the design, we took material stress density distribution analysis and found the low-stress area where we can remove the material while also considering manufacturing constraints. The modified geometry is then analyzed for the same loading conditions for stress and displacement pattern. Using the Normalized Material Density Distribution over the 32 Design Cycles Iteration, the optimized design is obtained, with red indicating retained part for application purposes.
Material Stress Density Distribution
Optimized Design of Steering Knuckle
Comparison of Results:
Displacement Distribution of Existing Component
Displacement Distribution of Optimized Model
Stress Analysis of Existing Component
Stress Analysis of Optimized Model
Results:
