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Page No:621 www.jrmat.com Vol 12, Issue4, 2021 ISSN NO: 0745-6999 JOURNAL OF RESOURCE MANAGEMENT AND TECHNOLOGY “DESIGN AND STATIC MODAL ANALYSIS OF STEERING KUNCKLE WITH VARIOUS MATERIALS USING FINITE ELEMENT METHOD” 1 RAVURI NAGA MANOHAR 2 Sri G.ANIL KUMAR 1 M.Tech student, Department of Mechanical Engineering, G.V.R & S College of Engineering and Technology, Guntur, Andhra Pradesh 2 Assistant Professor, Department of Mechanical Engineering, G.V.R & S College of Engineering and Technology, Guntur, Andhra Pradesh 1 [email protected] 2 [email protected] ABSTRACT Steering knuckle is one among important component of auto which is connected to steering, suspension and brake to chassis of auto . It undergoes different loading under different conditions. during this Project Main concept Over all concept of my project is light weight reduction ratio in main reason. we've done static analysis of steering knuckle. The Steering Knuckle component is that the most vital a part of vehicle which is connected to front wheel with the assistance of suspension , wheel hub and these also are connected to steering mechanism and brake to the chassis. The Steering Knuckle component provides motion to desire directions with the assistance of steering mechanism . It undergoes various sorts of varying load under different conditions. the planning of Steering Knuckle component is completed with the assistance of Computer Aided Engineering (CAE). The aim of the project is knuckle steering design is created in catia software and perform the static and modal analysis done in ANSYS WORKBENCH15.0 by constraining the steering knuckle and applying load on steering knuckle due to caliper mounting, longitudinal reaction, vertical reaction, vehicle weight and steering reaction. In this we have focused on optimizing the best use of material for the steering knuckle component and compare it, made from conventional materials AL2011T3, NIMONIC 80A, AL 7075 T6, GREY CAST IRON, Finally concluded the suitable material for the steering knuckle compared with recently using material Based on the static results Von-misses stress, strain, deformation, strain and Modal analysis find out the total deformation at different frequencies . 1.1 INTRODUCTION OF KNUCKLE STEERING A directing knuckle is the portion of the vehicle suspension that contains the wheel centre point or shaft and connects it to the suspension sections.It is differently called a controlling knuckle, shaft, upstanding or center, also. The haggle get together connect to the center point or axle of the knuckle where the tire/wheel turns while being held in a steady plane of movement by the knuckle/suspension gathering. The wheel get together is connected to the knuckle at its middle point. Note the arm of the knuckle that sticks out, to which the controlling component appends to turn the knuckle and wheel get together. Controlling knuckle is the basic part of the vehicle which is connected with suspension framework. It permits guiding arm to turn the front haggle likewise upholds the upward weight of the vehicle. When guiding is turn by drivers, half piece of the controlling knuckle part is exposed to malleable burden and one more half piece of directing knuckle part is exposed to compressive burden and because of this revolution of wheel, guiding knuckle is exposed to torsional load. The part of steering knuckle component are given below: 1. Suspension Mounting Upper Arm/Strut Mount 2. Tie Rod Mounting / Steering Arm 3. Lower Ball Joint /Suspension Mounting Lower Arm 4. Ball Bearing Location / Stub Hole 5. Brake Caliper Mounting 1.2 WORKING PRINCIPLE OF KNUCKLE STEERING: The directing knuckle is the association between the tie bar, stub hub and hub lodging. Directing knuckle is associated with the pivot lodging by utilizing head boss. One more end is associated with the tie pole. Then, at that point, the wheel center is fixed over the knuckle utilizing a direction. Guiding Knuckle is vehicle which joins suspension, directing framework, wheel center point and brake to the undercarriage. It goes through changing burdens exposed to various conditions, while not influencing vehicle directing execution and other wanted vehicle attributes. The capacity of the

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Page No:621 www.jrmat.com Vol 12, Issue4, 2021

ISSN NO: 0745-6999

JOURNAL OF RESOURCE MANAGEMENT AND TECHNOLOGY

“DESIGN AND STATIC MODAL ANALYSIS OF STEERING KUNCKLE

WITH VARIOUS MATERIALS USING FINITE ELEMENT METHOD”

1RAVURI NAGA MANOHAR 2Sri G.ANIL KUMAR 1M.Tech student, Department of Mechanical Engineering, G.V.R & S College of Engineering and

Technology, Guntur, Andhra Pradesh 2Assistant Professor, Department of Mechanical Engineering, G.V.R & S College of Engineering and

Technology, Guntur, Andhra Pradesh [email protected] [email protected]

ABSTRACT

Steering knuckle is one among important component of auto which is connected to steering, suspension and

brake to chassis of auto . It undergoes different loading under different conditions. during this Project Main

concept Over all concept of my project is light weight reduction ratio in main reason. we've done static

analysis of steering knuckle. The Steering Knuckle component is that the most vital a part of vehicle which is

connected to front wheel with the assistance of suspension , wheel hub and these also are connected to steering

mechanism and brake to the chassis. The Steering Knuckle component provides motion to desire directions

with the assistance of steering mechanism . It undergoes various sorts of varying load under different

conditions. the planning of Steering Knuckle component is completed with the assistance of Computer Aided

Engineering (CAE). The aim of the project is knuckle steering design is created in catia software and perform the

static and modal analysis done in ANSYS WORKBENCH15.0 by constraining the steering knuckle and applying

load on steering knuckle due to caliper mounting, longitudinal reaction, vertical reaction, vehicle weight and steering

reaction. In this we have focused on optimizing the best use of material for the steering knuckle component and

compare it, made from conventional materials AL2011T3, NIMONIC 80A, AL 7075 T6, GREY CAST IRON,

Finally concluded the suitable material for the steering knuckle compared with recently using material Based on the

static results Von-misses stress, strain, deformation, strain and Modal analysis find out the total deformation at

different frequencies .

1.1 INTRODUCTION OF KNUCKLE STEERING

A directing knuckle is the portion of the vehicle

suspension that contains the wheel centre point or shaft

and connects it to the suspension sections.It is differently

called a controlling knuckle, shaft, upstanding or center,

also. The haggle get together connect to the center point

or axle of the knuckle where the tire/wheel turns while

being held in a steady plane of movement by the

knuckle/suspension gathering. The wheel get together is

connected to the knuckle at its middle point. Note the

arm of the knuckle that sticks out, to which the

controlling component appends to turn the knuckle and

wheel get together. Controlling knuckle is the basic part

of the vehicle which is connected with suspension

framework. It permits guiding arm to turn the front

haggle likewise upholds the upward weight of the

vehicle. When guiding is turn by drivers, half piece of

the controlling knuckle part is exposed to malleable

burden and one more half piece of directing knuckle part

is exposed to compressive burden and because of this

revolution of wheel, guiding knuckle is exposed to

torsional load. The part of steering knuckle component

are given below:

1. Suspension Mounting Upper Arm/Strut Mount

2. Tie Rod Mounting / Steering Arm

3. Lower Ball Joint /Suspension Mounting Lower Arm

4. Ball Bearing Location / Stub Hole

5. Brake Caliper Mounting

1.2 WORKING PRINCIPLE OF KNUCKLE

STEERING:

The directing knuckle is the association

between the tie bar, stub hub and hub lodging. Directing

knuckle is associated with the pivot lodging by utilizing

head boss. One more end is associated with the tie pole.

Then, at that point, the wheel center is fixed over the

knuckle utilizing a direction. Guiding Knuckle is vehicle

which joins suspension, directing framework, wheel

center point and brake to the undercarriage. It goes

through changing burdens exposed to various conditions,

while not influencing vehicle directing execution and

other wanted vehicle attributes. The capacity of the

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guiding knuckle is to change over direct movement of

the tie bar into rakish movement of the stub hub.

The lighter controlling knuckle coming about

more noteworthy force and less the vibration due to the

inactivity is less. The directing knuckle passes on the

power push from join bar to the stub center and thusly it

ought to be uncommonly strong, inflexible and besides

as light as could truly be anticipated. On account of car

vehicle, during guiding and turning the directing knuckle

is exposed to compressive and pressure loads and

because of the wheel revolution it is additionally

exposed to torsional load. knuckle for auto applications

is commonly produced either by fashioning or from

projecting. Nonetheless, castings could have blow-

openings which are unfavorable according to strength

and weariness perspectives..

Figure 1 Parts of knuckle steering

1.3 STEERING KNUCKLE AND WHY IS IT

IMPORTANT

The controlling knuckle is stout piece of steel with a few

jutting arms found right behind your front wheels. It

associates the wheel center point (or axle) to the

suspension.

The circle brake caliper mounts to the knuckle.

Otherwise called a wheel transporter or an upstanding,

the controlling knuckle is the last part in the guiding

framework.

There's one guiding knuckle connected to each front

wheel, and its motivation is to turn your wheel when you

steer.

Figure 2 Knuckle steering placed in car

1.4 APPILICATIONS OF STEERING KNUCKLE:

In a non-drive suspension, as displayed in the primary

photograph, the knuckle typically has a shaft onto which

the brake drum or brake rotor connects. (In this image,

the focal axle whereupon the wheel get together rides

can't be seen.) The wheel/tire gathering then, at that

point, connects to the provided carry studs, and the entire

gathering turns openly on the shaft of the axle.

In a drive suspension, the knuckle has no axle, yet rather

has a center into which is appended the direction and

shaft of the drive component. The finish of the drive

instrument would then have the vital mounting studs for

the wheel/tire or potentially brake gathering. In this way,

the wheel gathering would pivot as the drive shaft (or

half-shaft) directs.

CHAPTER-2

LITERATURE REVIEW

AmeyaBhusari et al. (2015) thought about directing

knuckle for advancement. This activity's goal for

advancement is to reduce the weight of the guiding

knuckle.Regularly, the limited component programming

solidTHINK INSPIRE V9 (Solidworks) is used to

accomplish this reason. For streamlining,

Nastran/Ansys/Abaqus could likewise be utilized.The

designated weight or mass decrease for this activity is

about 62% without thinking twice about the primary

strength.

Viraj Rajendra Kulkarni his review centers around

streamlining of directing knuckle focusing on

lessening weight as target work, while not compromising

with required strength, recurrence and solidness.

Thinking about static and dynamic burden conditions,

underlying investigation and modular examination were

performed.

Purushottam Dumbre et al performed underlying

investigation on guiding knuckle for static condition

discovered the feeling of anxiety produced and utilized

geography enhancement to decrease the load by 11%

while meeting the strength prerequisite.

Kamlesh Lalsaheb Chavan et al.(2014) in this paper,

creator concentrated on the disappointment during

unexpected serious stacking caused because of misuse or

because of consistent and monotonous utilization while

driving for broadened timetable over the existence of the

part. The test modeled for the Design Engineer is to

reproduce the real conditions during the examination

stage and decide the best material or the determinations

of the part that would be generally fit to the given

application. The current Design challenge for the

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Steering Knuckle Arm is to produce the most ideal

arrangement of the part Design for the given information

states of stacking. The Sponsoring Company is dealing

with the destined to be dispatched auto model and is

relied upon to take this assignment to culmination using

CAD (CATIA or UG) for making the math and further

utilize the CAE devices (HyperWorks/Optistruct/or

appropriate) for leading examination for the part. The

Test Report/s for the part would shape a reason for

confirming the outcomes with the Analytical strategy for

investigation. For approving the Design of the part, a

decent match of the comparing readings is wanted.

Commonly, contingent upon the sort of Test and the

application, a blunder edge or around 5 to 20% could be

viewed as close towards approving the proposed

Plan. Mahendra L. Shelar and H. P. Khairnar (2014) in

this paper creator had recognized the issue of interaction

advancing the plan utilizing a procedure dependent on

strength and plan enhancement through probabilistic

models of plan factors (DOE). Their review manages

production of mathematical model of directing knuckle

(LUV) in strong works after that that model will be

imported to NFX Nastran for limited component

demonstrating where the cross section properties,

component properties will be created. Loads and model

conditions applied to demonstrate there by producing

document that record will be submitted to solver

(Nastran) and straight static primary investigation will be

performed. To direct model examination to comprehend

the unique conduct of the construction and subsequently

followed by transient primary reaction investigation. At

the point when advanced model is contrasted and starting

model, 9.195% Reduction in weight has been

accomplished with pressure and avoidance change inside

range and not surpassing over the Project target limits.

Tagade, P. et al. (2015) in this paper, creators meant to a

light weight and upgraded plan of controlling knuckle is

proposed to be utilized for an EIMARace vehicle; a little

superior recipe style vehicle, with reasonable material

determination just as substantial limited component

investigation and streamlining examines. Initial segment

of this review includes demonstrating of directing

knuckles and investigation of the burdens and removal

under genuine burden conditions. A CAD and FEA

programming; Solid Works, is applied for demonstrating

just as for static examination considers. Shape

streamlining is the second piece of this review, using

strong Thinking programming from Altair Engineering

bundles. As a definitive point of this review is to lessen

mass of the current knuckle with focus to accomplish

low fuel utilization, choice of the best material and

straightforward calculation are essential. Aluminum

6061-T651 composite (yield strength 276 MPa) was

observed to be the best material for the part because of

the great physical and mechanical properties just as light

weight. Get the best utilization of material for the part

was supported in lessening the heaviness of existing

knuckle to 45.8% while meeting the strength necessity.

The insignificant load of the guiding knuckle part might

add to the decrease of the general load of the race

vehicle hence may further develop the eco-friendliness

just as the general execution.

Wan Mansor Wan Muhammad et al. (2012) in this paper

limited component programming, HyperWorks which

contains a few modules is utilized to accomplish this

goal. HyperMesh was utilized to set up the limited

component model while HyperMorph was used for

characterizing shape factors. For streamlining reason,

OptiStruct was used. The further developed plan

accomplishes 8.4% decrease of mass. Despite the fact

that there are volume decrease and shape changes, most

extreme pressure has not change fundamentally. This

outcome is palatable thinking about utilizing

advancement fit as a fiddle just, with restricted plan

space given and no adjustment of material properties.

Advancement strategy utilized in this review prevailed

with regards to diminishing the mass of existing knuckle

part to 8.4%. Despite the fact that there are volume

decrease and shape changes, most extreme pressure has

not change fundamentally. This outcome is palatable

thinking about utilizing enhancement fit as a fiddle just,

with restricted plan space given and no adjustment of

material properties. Other vehicle parts, also, can

possibly be diminished regarding mass utilizing shape

improvement. Hence, the general load of the vehicle can

be diminished to accomplish reserve funds in expenses

and materials, just as, further develop eco-friendliness

and decrease fossil fuel byproducts to support the

climate.

Rajkumar Roy et. al. (2008) center around late ways to

deal with mechanizing the manual improvement measure

and the difficulties that it presents to the designing local

area. The review distinguishes versatility as the

significant test for plan enhancement methods. GAs is

the most famous algorithmic streamlining approach.

Huge scope streamlining will require more examination

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in geography plan, computational force and proficient

enhancement calculations.

CHAPTER-3

OBJECTIVE OF THE PROJECT

3.1 SCOPE OF THE PROJECT

Design of the knuckle controlling utilizing the catia

programming.

Perform static and modular Analysis by utilizing the

ansys programming .

Perform the investigation utilizing different materials.

Find out the burdens, twisting in static examination and

discover the misshapenings at various frequencies in

modular anlaysis.

Conclude the best material for the knuckle directing.

3.2 METHODOLOGY OF THE PROJECT

At first the review writing study for the controlling

knuckle gathered and afterward the issue proclamation is

shaped and afterward the underlying idea of the knuckle

is framed. Then, at that point, the displaying of the

knuckle is begun by fixing the rotating appendages and

the stub hub measurement and finished with the

assistance of catia v5 programming Different models of

the ideas are created by utilizing enhancement materials

idea and they are dissected for primary investigation

utilizing Ansys. The review is on demonstrating a

suspension framework and the examination of its

Vonmisses stresses, shear pressure, Total misshapening,

Strain included and dislodging under arbitrary stacking

conditions.

Utilizing various materials AL2011T3, NIMONIC 80A,

AL 7075 T6, Gray CAST IRON and CAD models of the

suspension arrangement of a vehicle were created with a

3D displaying programming and play out the static and

modular investigation utilizing ansys programming. The

pressure examination of the models were gotten and

contrasted utilizing FEA with Ansya16 programming

with advance for weight decrease. At last close the

appropriate material dependent on the anxieties,

distortion esteems.

3.3 PROBLEM IDENTIFICATION

Improper material prompts the disappointment

Weight decrease is generally significant in car field

Steering knuckle requires loads of consideration in

choice in light of the fact that whenever it is harmed then

it need to supplant with the upgraded one. This issue can

be addressed by overhauling the directing knuckle.

Along these lines, the directing knuckle can be made

minimal by coordinating with shaft which helps in great

guiding

Figure 3.1 Animation of knuckle steering

• Your wheel arrangement will be tossed messed

up. This prompts lopsided tire wear and helpless taking

care of.

• The harmed part can put extra weight ready

joints. Rotating appendages can break unexpectedly.

On the off chance that a rotating appendage breaks, it

will unexpectedly turn out to be extremely challenging to

guide, and you might free control of the vehicle. This is

clearly exceptionally risky. In the event that you

speculate that a controlling knuckle is harmed, you ought

to investigate it right away.

3.4 DESIGN OF STEERING KNUCKLE

(A) Calculation of Load

i). Axial Loads:

There are two axial load acting on the steering knuckle

such as tensile load and compressive load.

The stress due to this load can be findout using the

following formula,

Tensile Load ( )= Tensile stress × Area

Compressive Load ( ) = Compressive stress ×Area.

ii). Inertia Load:

This load act on Steering Knuckle due to the inertia of

the moving parts .The inertia load can be find out using

the following formula,

iii). Bending Load

This load acts on the steering knuckle due to the weight

of the vehicle and this tends to bend the steering knuckle

outward away from the centerline .Total inertia bending

load is given by,

(B) Calculation of Stresses

i). Stress Due to Axial Loads The force of resistance per

unit area, offered by a body against deformation is

known as stress. This is given by,

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ii). Stress because of Inertia twisting power Inertia

bowing burden sets up a pressure which would be

malleable on one side of the knuckle and compressive on

another side and that these pressure change sign every

half unrest .The bowing second at any part 'X' m from

the little end is given by,

(C) Loading Condition on Knuckle

For the calculation of load acting on steering knuckle

component, the required loading condition which are

follows:

Table3.1:Loading Condition on Steering Knuckle

If the knuckle is design for the vehicle of 1240kg weight

.Thus braking force acting on it produced moment. This

calculated as,

Braking force = 1.5mg

= 1.5×310×9.81

= 4561.65 N

For calculation braking force acting on one wheel

i.e.1240/4=310kg for one wheel and perpendicular

distance is 94mm considered.

Moment = Braking force × perpendicular distance

= 4561.65×94

= 428795.1 N-mm (for one wheel)

This moment is acting on steering knuckle where

breakcaliper is mounted .Since all loads act in X, Y and

Z direction are perpendicular to each other as shown in

figures

Thus the resultant force is given by,

3.5 MATERIAL PROPERTIES:

3.5.1 AL2011T3 MATERIAL:

Aluminum amalgam 2011 is a high mechanical strength

compound that machines extraordinarily well.

Machining at high velocities delivers fine chips that are

handily taken out. The amazing machining qualities

permit the creation of complicated and point by point

parts.

Applications - 2011 is normally utilized in applications

that require parts made by reiteration machining. These

applications might include:

Appliance parts & trim

Automotive trim

Fasteners and fittings

Ordnance

3.5.2 NIMONIC 80A MATERIAL:

NIMONIC 80A is typically provided in the at last

warmth treated condition (extinguished and tempered to

"T" properties) NIMONIC 80A is an exceptionally

famous grade of through the "T" condition. (Allude to

our machinability). NIMONIC 80A is generally

appropriate for the assembling of parts like substantial

axles and shafts, pinion wheels, bolts and studs.

3.5.3 AL 7075 T6 MATERIAL:

General 7075 attributes and uses (from Alcoa): Very

high strength material utilized for exceptionally focused

on primary parts. The T7351 temper offers further

developed pressure erosion breaking obstruction.

3.5.4 GREY CAST IRON MATERIAL:

Table 3.2 :MATERIAL PROPERTIES

CHAPTER-4

4.1 INTRODUCTION TO CATIA

Welcome to CATIA (Computer Aided Three

Dimensional Interactive Application). As again client of

this product bundle, you will hold hands with large

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number of clients of this very good quality

CAD/CAM/CAE device around the world. In case you

are now acquainted with the past discharges, you can

redesign your planning abilities with the enormous

improvement in this most recent delivery.

CATIA V5, created by Dasssault Systems, France, is a

totally re-designed, Next-age group of CAD/CAM/CAE

programming answers for Product Lifecycle

Management. Through its especially simple to-utilize

and best in class UI, CATIA V5 conveys inventive

advancements for greatest efficiency and imagination,

from the origin idea to the end result. CATIA V5 lessens

the expectation to learn and adapt, as it permits the

adaptability of utilizing highlight

4.2 CATIA V5 WORKBENCHES

CATIA V5 serves the essential plan undertakings by

giving various workbenches. A workbench is

characterized as a predefined climate comprising of a

bunch of devices that permits the client to

performspecific configuration assignments. The essential

workbenches in CATIA V5 are Part Design, Wireframe

andSurface Design, Assembly Design,Drafting.

4.3 DIMENSIONS AND DESIGN PROCEDURE IN

CATIA:

Guiding knuckle part was made in 3D displaying

programming catia. It comprises of Stub opening Brake

Caliper mounting focuses, Steering tie-pole mounting,

Suspension upper arm mounting and Suspension lower

arm mounting. Directing knuckle part configuration

primarily relies upon suspension framework calculation

and controlling math. The plan additionally needs to

follow the measures and guidelines, which the size ought

to be basically relies upon suspension framework.

Figure 4.1 Dimensions of knuckle steering

Figure 4.2 Isometric view in catia

Figure 4.3 Multiviews in catia workbench

CHAPTER-5

FINITE ELEMENT METHOD

5.1 INTRODUCTION

The Basic idea in FEA is that the body or

design might be separated into more modest components

of limited measurements called "Limited Elements". The

first body or the design is then considered as a gathering

of these components associated at a limited number of

joints called "Hubs" or "Nodal Points". Straightforward

capacities are picked to surmised the relocations over

each limited component. Such accepted capacities are

designated "shape capacities". This will address the

relocation with in the component as far as the uprooting

at the hubs of the component.

The Finite Element Method is a numerical

apparatus for tackling conventional and fractional

differential conditions. Since it is a mathematical

apparatus, it can take care of the complicated issues that

can be addressed in differential conditions structure. The

utilizations of FEM are boundless as respects the

arrangement of functional plan issues.

5.2 THE BASIC STEPS INVOLVED IN FEA

Numerically, the design to be investigated is partitioned

into a cross section of limited estimated components of

straightforward shape. Inside every component, the

variety of uprooting is thought not really settled by

straightforward polynomial shape ,

Basic Steps in FEA

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Discretization of the domain

Application of Boundary conditions

Assembling the system equations

Solution for system equations

Post processing the results.

What is an Element?

Component is a substance, into which a framework

under study can be isolated into. Hubs can determine a

component definition. The shape (region, length, and

volume) of the component relies on the hubs with which

it is comprised of.

What are Nodes?

Hubs are the corner points of the component. Hubs are

autonomous substances in the space. These are like

focuses in calculation. By moving a hub in space a

component shape can be changed. This is a volume

component, can take the state of a Hexahedron or a

Wedge or a Tetrahedron request components.

5.3 ANALYSIS PROCEDURE IN ANSYS:

Designed component in catia workbench after imported

into ansys workbench now select the steady state thermal

analysis .

1.ENGINEEERING MATERIALS (MATERIAL

PROPERTIES).

2.CREATE OR IMPORT GEOMENTRY.

3.MODEL(APPLY MESHING).

4.SET UP(BOUNDARY CONDITIONS)

5.SOLUTION

5.4 STATIC STRUCTURAL ANALYSIS

The static structural analysis calculates the stresses,

displacements, strains, and forces in systems because of

a load that doesn't set off considerable inertia and

damping outcomes. constant loading and response

situations are assumed; that the hundreds and the

structure’s response are assumed to alternate slowly with

recognize to time.

5.5 MODAL ANAYSIS:

In modal analysis free herbal vibration frequencies of

steering knuckle became located out for the primary 3

modes maintaining the suspension individuals and the

attached member of the mounts confined. all the modes

that were found out have been rigid body mode.

MESH

Figure 5.1 meshing of knuckle steering

MESH :NODES:8505

,ELEMENTS :4414

5.6 BOUNDARY CONDITIONS:

The boundary conditions for the Steering Knuckle and

apply axial load, inertia load, moments and forces as

shown below figure

Figure 5.2 Boundary conditions of knuckle steering

CHAPTER-6

RESULTS AND DISCUSSIONS

6.1 STATIC AND MODAL ANALYSIS RESULTS:

The evaluation of guidance knuckle factor is completed

in ansys workbench 16.0. the specified load of guidance

knuckle aspect become decide from diverse studies

papers. according to papers we assume average weight

of motors is 1240 kg. with special materials Nimonic

80A, al 7075 t6, gray forged iron .the load are at once

acted on all the 4 knuckle. as a consequence the load of

cars acted on one wheel is 310 kg.

6.1.1 STATIC ANALYSIS OF GREY CAST IRON

MATERIAL:

Figure 6.1 Von-misses stress of grey cast iron material

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Figure 6.2 Total deformation of grey cast iron material

Fig 6.3 Total deformation of Grey cast iron material

6.1.2 STATIC ANALYSIS OF Al 7075 T6

MATERIAL:

Figure 6.4 Von-misses stress of Al 7075-T6 Material

Figure6.5 Total deformation of Al 7075-T6 Material

6.1.3 STATIC ANALYSIS OF NIMONIC 80A

MATERIAL:

Figure 6.6 Von-misses stress of Nimonic 80A Material

Figure 6.7 Shear stress of Nimonic 80A Material

6.2 MODAL ANALYSIS

6.2.1 MODAL ANAYSIS OF GREY CAST IRON

Figure6.8 MODE 1

Figure6.9 MODE 2

6.2.2 MODAL ANALYSIS OF NIMONIC 80A

MATERIAL:

Figure 6.10 MODE 1

6.2.3 MODAL ANALYSIS OF Al 7075 T6

MATERIAL:

Figure 6.11 MODE 1

Figure6.12 MODE 2

Figure 6.13 MODE 3

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6.3 STATIC AND MODAL ANALYSIS GRAPHS:

From below figure, we can observe that in case of

equivalent (von-misses) stress, Total deformation, shear

stress, strain Steering knuckle applied different forces

and moments fixed at one end finally generate the graphs

with different materials NIMONIC 80A, AL 7075 T6,

GREY CAST IRON as shown below graphs

Figure 6.14 Von-misses stresses with different

materials

Figure 6.15 Total deformation with different materials

Figure 6.16 Strain graph with different materials

Figure 6.17 Shear stress with different materials

6.4 MODAL ANALYSIS GRAPHS

Figure 6.18 MODAL ANALYSIS OF GREY CAST IRON

Figure 6.19 MODAL ANALYSIS OF Al 7075 T6 Material

CHAPTER-7

CONCLUSION

The design of Steering Knuckle component is done with

the help of Computer Aided Engineering (CAE).

Steering Knuckle model is prepare in catia and the static

analysis and modal analysis is done in ANSYS

WORKBENCH15.0 by constraining the steering knuckle

and applying load on steering knuckle due to caliper

mounting, longitudinal reaction, vertical reaction,

vehicle weight and steering reaction. In this we have

focused on optimizing the best use of material for the

steering knuckle component and compare it, made from

conventional and composite materials AL2011T3,

NIMONIC 80A, AL 7075 T6, GREY CAST IRON,

Finally concluded NIMONIC 80A and Al 7075 is the

suitable materials because less stress and deformation

modal analysis(frequencies and total deformation) is also

satisfied so concluded the NIMONIC 80A and Al 7075

is suitable for manufacturing for the steering knuckle

compared with recently using material Grey cast iron

because of reduced the overall weight of vehicles due to

decrease in weight of steering knuckle component as

well as save the materials and cost and improved the

vehicles performance and fuel economy

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