International Journal of Emerging Technology and Advanced Engineering

Website: www.ijetae.com (ISSN 2250-2459, ISO 9001:2008 Certified Journal, Volume 4, Issue 6, June 2014)
552

Structural Analysis of Steering Knuckle for Weight Reduction
Purushottam Dumbre
1
, A. K. Mishra
2
, V. S. Aher
3

1
Amrutvahini College of Engineering, Sangamner.
2
Prof and Head of Mechanical Engg. Dept. AVCOE, Sangamner

3
Asst. Prof. Department of Mechanical Engineering, AVCOE, Sangamner
Abstract--The weight of the vehicle is going on increasing
due to additional luxurious and safety features. The
increasing weight of the vehicle affects the fuel efficiency and
overall performance of the vehicle. Therefore the weight
reduction of the vehicle is the real need of todays automotive
industry. Steering knuckle is one of critical component of
vehicle. It links suspension, steering system, wheel hub and
brake to the chassis. There is scope to reduce the un sprung
weight vehicle. Steering Knuckle is a non-standard part and
subjected to various loads at different conditions. Weight
reduction of steering knuckle is the objective of this exercise
for optimization. Typically, the finite element software like
OptiStruct (Hyper Works) is utilized to achieve this purpose.
For optimization, Nastran / Ansys / Abaqus could also be
utilized. The targeted weight or mass reduction for this
exercise is about 5% without compromising on the structural
strength.
Keywords- un sprung weight, Steering Knuckle,
I. INTRODUCTION
The steering knuckle on your vehicle is a joint that
allows the steering arm to turn the front wheels. The forces
exerted on this assembly are of cyclic nature as the steering
arm is turned to maneuver the vehicle to the left or to the
right and to the centre again.
Steering knuckles come in all shapes and sizes. Their
designs differ to fit all sorts of applications and suspension
types. However, they can be divided into two main types.
One comes with a hub and the other comes with a spindle.
In this investigation, steering knuckle was used as
component for study. Mass or weight reduction is
becoming important issue in car manufacturing industry.
Weight reduction will give substantial impact to fuel
efficiency, efforts to reduce emissions and therefore, save
environment. Weight can be reduced through several types
of technological improvements, such as advances in
materials, design and analysis methods, fabrication
processes and optimization techniques, etc. Steering
Knuckle is subjected to time varying loads during its
service life, leading to fatigue failure. Therefore, its design
is an important aspect in the product development cycle.
Automotive makers continuously develop new vehicles
with more luxury, convenience, performance, and safety.
Often, they reduce vehicle weights which results in reduced
energy consumption. A reduction in the weight of
suspension components also improves the vehicles
handling performance. Therefore, design optimization
should be implemented to obtain a minimum weight with
maximum or feasible performance, based on conflicting
constraints, design boundaries, and design uncertainties,
such as design clearance and material defects. Among the
vehicle structural components, the knuckle is one of the
important parts in the suspension system. It plays a crucial
role in minimizing the vertical and roll motion of the
vehicle body, which implies a poor passenger experience,
when a vehicle is driven on a rough road. A knuckle
component is required to support the load and torque
induced by bumping, braking, and acceleration and also
helps in steering the tire connecting tie rod and rotating at
the kingpins axis centre. In the design optimization of the
knuckle component, a weight should be minimized, while
design factors such as strength, stiffness and durability
should be satisfied with design targets. The steering
knuckle accounts for maximum amount of weight of all
suspension components, which requires high necessity of
weight reduction. Under operating condition is subjected to
dynamic forces transmitted from strut and wheel. The
weight reduction of steering knuckle is done such that the
strength, stiffness and life cycle performance of the steering
knuckle are satisfied.
II. LITERATURE SURVEY
1. A workshop report published by an agency of the United
States government (Feb2013) focused on the development
in light weighting and the technology gap for light duty
vehicle. Also the set the goal for weight of vehicle for year
2020 to 2050.The target for reduction of weight of LDV
chassis and suspension system is 25% by the year2020.
2. RajkumarRoy et. al.(2008)focus on recent approaches to
automating the manual optimization process and the
challenges that it presents to the engineering community.

International Journal of Emerging Technology and Advanced Engineering
Website: www.ijetae.com (ISSN 2250-2459, ISO 9001:2008 Certified Journal, Volume 4, Issue 6, June 2014)
553

The study identifies scalability as the major challenge for
design optimization techniques. GAs is the most popular
algorithmic optimization approach. Large-scale
optimization will require more research in topology design,
computational power and efficient optimization algorithms.
3. S. Vijayaranganet.al.(2013) uses the different material
than regular material for optimization of steering knuckle.
They use Metal Matrix Composites (MMCs) as it have
potential to meet demanded design requirements of the
automotive industry, compared with conventional
materials. Structural analysis of steering knuckle made of
alternate material Al-10 wt% Tic was performed using
commercial code ANSYS. It is found from the analysis; the
knuckle strut region has maximum stress and deflection
during its life time. The results obtained from numerical
analysis and experimental testing using particulate
reinforced MMCs for steering knuckle with a weight
saving about 55% when compare with currently used SG
iron.
4. Prof.R. L. Jhala et. al. (2009) assesses fatigue life and
compares fatigue performance of steering knuckles made
from three materials of different manufacturing processes.
These include forged steel, cast aluminum, and cast iron
knuckles. Finite element models of the steering knuckles
were also analyzed to obtain stress distributions in each
component. Based on the results of component testing and
finite element analysis, fatigue behaviors of the three
materials and manufacturing processes are then compared.
They conclude with that forged steel knuckle exhibits
superior fatigue behavior, compared to the cast iron and
cast aluminum knuckles.
5. k. h. Chang and P.S. Tang(2001) discuss an integrated
design and manufacturing approach that supports the shape
optimization. The main contribution of the work is
incorporating manufacturing in the design process, where
manufacturing cost is considered for design. The design
problem must be formulated more realistically by
incorporating the manufacturing cost as either the objective
function or constrain function.
6. Patel Nirala and Mihir Chauhan(2013) carry out the
topology optimization of clamp cylinder t using CAE tools
to reduce weight with the constraints of standard operating
condition. The new optimized design of configuration is
proposed.FEA of optimized cylinder is also carried out and
compared with acceptance criterion. The optimized model
is equally strong and light in weight compared to existing
model.
The topology optimization of the component is carried out
and substantial reduction in weight about 70 kg is obtained
and also obtained stress and deformation within acceptance
criteria.
7. Rajeev Sakunthala Rajendran et. al. (2013) discuss the
process of designing a light weight knuckle from scratch.
The design space is identified for the knuckle and
subsequently a design volume satisfying the packaging
requirements is created from it. Using Opti Struct, topology
optimization is performed on the design volume to derive
the optimal load path required for the major load cases.
Hypermorph is used to create the required shape variable
and Hyper Study is used as optimizer. The process of using
Topology optimization for load path generation&
Parametric study using shape optimization, reduces the
design iteration and intermediate concept models and there
by reduces the design cycle time.
There are four disciplines for optimization process:
Topology optimization: It is an optimization process which
gives the optimum material layout according to the design
space and loading case.
Shape optimization: This optimization gives the optimum
fillets and the optimum outer dimensions.
Size optimization: The aim of applying this optimization
process is to obtain the optimum thickness of the
component.
Topography: It is an advanced form of shape optimization,
in which a design region is defined and a pattern of shape
variable will generate the reinforcements.
III. METHODOLOGY
The normal mode analysis and stiffness of the steering
knuckle is obtained using finite element analysis. Finite
element modeling is done using HYPERMESH and the
necessary boundary conditions and material are imposed on
it. The setup is solved using RADIOSS solver. Weight
reduction is done using optimization software
OPTISTRUCT. The weight reduction is done using
Topology optimization by meeting the strength, stiffness
and vibration targets. And the corresponding weight
reduction is analyzed. The design direction given by the
OPTISTRUCT is used to do the design modifications and
with few iterations, the optimized design satisfying all the
strength, stiffness, vibration & life-cycle performance
criteria is evolved.

International Journal of Emerging Technology and Advanced Engineering
Website: www.ijetae.com (ISSN 2250-2459, ISO 9001:2008 Certified Journal, Volume 4, Issue 6, June 2014)
554

The design is validated further by performing linear
static analysis and normal mode analysis using RADIOSS.
The complete approach is shown in flow chart.











IV. DESIGNING A CAD MODEL
CAD model of steering knuckle was developed in 3D
modeling software CATIA. it consists of stub hole, brake
caliper mounting points, steering tie-rod mounting points,
suspension upper and lower A-arm mounting points.
Knuckle design mainly depends on suspension geometry
and steering geometry.
V. MATERIAL SELECTION
There are several materials used for manufacturing of
steering knuckle such as S.G. iron (ductile iron), white cast
iron and grey cast iron. But grey cast iron mostly used.
Forged steel are most demanding material for this
application. For this Ferrite ductile iron is used
VI. MESHING
CAD model of knuckle converted into STEP file. This
model is imported into Abaqus Workbench simulation.
Geometry cleanup was performed prior to meshing of
model. Optistruct is used as solver. For better quality of
mesh fine element size is selected.
Table 1.
Nodes and Elements of model
Element C3D10
No. of Element 55689
Nodes 93694
Material M122-HSS180- max

Fig.1. Meshing of model
The base geometry is simulated for the actual loading
conditions. The load conditions are obtained from data
acquisition system. The loadings are as follows.

Fig.2.Loading conditions


International Journal of Emerging Technology and Advanced Engineering
Website: www.ijetae.com (ISSN 2250-2459, ISO 9001:2008 Certified Journal, Volume 4, Issue 6, June 2014)
555


Fig.3. Displacement Contour

Fig.4. Stress Contour
After the analysis of base model the maximum
displacement is found to be 0.2 mm in the brake clamping
holding area as shown in fig.3 The maximum stress is
found in junction area brake clamping and shock absorb
connecting arm as shown in fig.4
The material density distribution is observed for finding
the low stress area where we can modify the geometry.
Fig.5 shows the low stress area where we can remove
material that not bear the load. For removal of material we
have to consider the manufacturing aspect and some
functional constraint. The feasibility of tooling required for
modified geometry should check at the time of material
removal.
The geometry after material removal is shown in fig.6
The new geometry is analyzed for the same loading
conditions and observed for displacement and stress
pattern.





Fig.5. Material Density Distribution

Fig.6. Modified Geometry
VII. OBSERVATIONS
It is observed that the maximum displacement and the
maximum stress are induced in the same region as that in
the earlier geometry that means the stress pattern remains
same. The values are below the safe values.

International Journal of Emerging Technology and Advanced Engineering
Website: www.ijetae.com (ISSN 2250-2459, ISO 9001:2008 Certified Journal, Volume 4, Issue 6, June 2014)
556


Fig.7. Displacement contour of modified model

Fig.7. Stresst contour of modified model
VIII. RESULT
Initial model of knuckle is shown in Fig.4. It has max.
Stress of 232.7 MPa. After applying load and design
constraints topology optimization was performed. Fig.6
shows material which can be removed from model (shown
in light green) after optimization.
The mass reduction for the front knuckle was found to
be 11%, compared to the currently used model. Optimized
model is shown in fig.7 This result is satisfactory
considering using topology optimization, with limited
design space given and no change in material properties.
Summary of results is shown in Table 2.
Table 2
Summery Of Result

Initial
Design
Optimised
Design
%
Reduction
Displacement 0.2 mm 0.21mm
Stress 232.7 MPa 223 MPa
Masss 2.91 Kg 2.6 Kg 11 %
IX. CONCLUSION
Topology optimization can be used to reduce the weight
of existing knuckle component by 11% while meeting the
strength requirement, with limited design space given with
or without change in material properties. Therefore, the
overall weight of the vehicle can be reduced to achieve
savings in raw material costs and consequently processing
cost, as well as, improve fuel efficiency and reduce carbon
emissions to help sustain the environment.
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International Journal of Emerging Technology and Advanced Engineering
Website: www.ijetae.com (ISSN 2250-2459, ISO 9001:2008 Certified Journal, Volume 4, Issue 6, June 2014)
557

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