Topology optimization of vehicle steering knukle by using altair inspire

Zaharuddin, Mohd Khairuddin (2025) Topology optimization of vehicle steering knukle by using altair inspire. Project Report. Universiti Teknikal Malaysia Melaka, Melaka, Malaysia. (Submitted)

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Abstract

Steering knuckles are important components of the steering system, essential for maintaining vehicle stability as well as controlling steering. This research analyses the topological optimization of a vehicle steering knuckle with Altair Inspire to optimize structural performance, weight, and improve fuel efficiency. The steering knuckle, a necessary component connecting suspension, steering, and braking systems, has to possess an optimal combination of strength, durability, and lightweight characteristics according to safety and operational requirements. The analysis begins with the reverse engineering process by using the EX-Scan Pro system to scan the component, followed by complex CAD modelling in CATIA V5. Structural analysis, including stress distribution and displacement analysis, is conducted with Finite Element Analysis (FEA). Topology optimization methodologies are used to improve geometry and reduce weight while maintaining structural integrity. Furthermore, lattice structures are used to improve mechanical performance. The results show that optimizing topology and lattice structures significantly decreases component weight without compromising strength, hence enhancing fuel efficiency and supporting sustainable automotive methods of design.

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