The article describes the creation of a 3D model of the steering knuckle of the “Formula Student” class car using the SolidEdge CAD / CAE system application, named generative design. The initial data are a model of an overly strong steering knuckle, previously calculated load values for various operating modes, information about the properties of the material. In the process of optimization, technological settings are varied in order to obtain a geometry that is as suitable as possible for cutting on a three-axis milling machine with a CNC and without an additional rotary axis. The result of the generative design is used to build a model of a knuckle that can be milled with repositioning and clamped into universal fixtures such as a vise. The construction is carried out using standard solid modeling tools (lofting by sections, adding thickness, etc.). Fastening elements have been added to the part, in the form of rectangular bodies, which will need to be removed using manual cutting and grinding operations after the milling operations are completed. Additionally, holes are removed parallel to the Z axis, which can only be made after cutting the fasteners.

The paper describes the calculation of input parameters for static strength analysis or generative design of the steering knuckle of a Formula Student race car. The initial data were: overall and mounting dimensions of the rim and tire, hub and brake disk, the magnitude of the force acting on the contact patch of the wheel with the road, the magnitude of the sliding friction force between the brake disk and brake pads, the force acting on the tie rod attachment, the location coordinates ball joint mounts and brake caliper. During the calculations, bearings were selected and forces on the coordinate axes were calculated, which must be applied to the part to simulate work loads. The calculation was performed by static methods. As a result, six load cases were obtained, simulating work in right and left turns with oversteer and understeer, as well as work during braking with maximum negative acceleration. Also, a 3D model of the steering knuckle was built, which has excessive strength (factor of safety is higher than 6). Padding values of the unchangeable areas have been defined, that prevent the generative design algorithm from subtracting material from important structural features of the part. The offset values were verified using additional finite element calculations.

The article demonstrate the technique for modeling the form of natural oscillations, as well as the amplitude and mode of forced oscillations of the HAAS VF-1 vertical milling machine. As initial data, a publicly available 3D model of load-bearing elements, information on the mass and dimensions of the spindle motor are used. In preparation for the simulation, the original solid model is idealized by removing small chamfers, fillets, and small diameter holes. Movable joints with linear rolling guides and ball bearings are replaced by rigid joints, since vibration damping in these units is not considered. During the first simulation, ten natural frequencies with the largest values of the oscillation amplitude are obtained. The second simulation shows, the influence of the spindle drive layout (coaxial installation of the electric motor with the spindle through a cam clutch or connection using a toothed belt transmission) and additional devices for dissipating vibration energy (mass and structural dampers in the form of structural elements articulated through plastic bushings) is revealed by the magnitude of forced steady-state oscillations that may occur during the processing of the part.