“design and static modal analysis of steering kunckle …
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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
REFERENCES
[1] Purushottam Dumbre, Prof A.K.Mishra, V.S.Aher,
Swapnil S. Kulkarni, “Structural Analysis Of Steering
Knuckle For Weight Reduction”, International Journal of
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