Calculation of Input Parameterts for Topology Optimisation of Steering Knuckle

Abstract

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.