FEA-Based Design and Evaluation of a Steering Knuckle Joint

The steering knuckle is a unique component that links the suspension, steering, braking systems, and wheel hub to the vehicle chassis. It bears vertical loads and is crucial for directional control. Given the diverse loads encountered in various situations, it is imperative to ensure high quality, durability, and precision without affecting the steering performance or the vehicle\\\'s overall behavior. In the automotive sector, reducing fuel consumption and achieving lightweight designs are critical requirements. A lighter steering knuckle improves performance and reduces production costs. This study aimed to optimize the material used for the steering knuckle joint. Currently, it is constructed from spheroidal cast iron, which provides good strength but is heavy and less resistant to corrosion than other materials. Thus, selecting a material with improved corrosion resistance and lower weight is necessary. The proposed approach investigates the use of Al matrix composites. Initially, the knuckle was designed analytically using mathematical equations. Subsequently, FEA was conducted for all alternative materials, and material optimization was performed. An experimental investigation was conducted to validate the results obtained from the FEA. Keywords: Steering Knuckle, Optimization, FEA, Matrix Composites, Lightweight Design.