A new design concept of lightweight knuckle for B-segment passenger car

Mohamad Daud, Alif Aiman (2019) A new design concept of lightweight knuckle for B-segment passenger car. Project Report. Universiti Teknikal Malaysia Melaka, Melaka, Malaysia. (Submitted)

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Abstract

Steering knuckle is a component that attached to the steering and braking system, wheel hub to the chassis and suspension. It is a very critical component and requires high quality, durability and precision. In automotive industry, the main issue of this component is weightiness due to increasing safety features on a vehicle. It is so important to reduce mass of vehicle component that will automatically contribute to the reduction of the vehicle’s mass and this will improve the energy consumption and power efficiency. So, the main objective of this research is to propose a new concept design by using different material and reduce weight of the existing steering knuckle by applying topology optimization technique. For redesign process, CATIA V5 will be used and solid thinking will be used for optimization process and strength analysis process. For optimization process, the weight must be reducing at least 20% from the original component and not compromising the strength of the component which is the safety factor must be above 1.2. At the end, the maximum stress does not exceed yield stress and ultimate tensile strength for linear and nonlinear loadcases respectively.

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