Lightweight Design and Analysis of Steering Knuckle of Formula Student Car Using Topology Optimization Method

Hasan, Ammarul; Lu, Cunhao; Liu, Wei

doi:10.3390/wevj14090233

Cited by 6 publications

(4 citation statements)

References 17 publications

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“…In this paper, topology optimization is adopted to achieve the lightweight design of the boss. Topology optimization is a design method to determine the optimal structural type, which aims to minimize the weight of the structure while maintaining its performance and strength by redistributing the layout of materials and has been widely used in the field of engineering design [36,37].…”

Section: Experimental Verificationmentioning

confidence: 99%

Lightweight Type-IV Hydrogen Storage Vessel Boss Based on Optimal Sealing Structure

Shao,

Wang,

et al. 2024

WEVJ

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The seal and weight of the Type IV hydrogen storage vessel are the key problems restricting the safety and driving range of fuel cell vehicles. The boss, as a metal medium connecting the inner liner of the Type IV hydrogen storage vessel with the external pipeline, affects the sealing performance of the Type IV hydrogen storage vessel, and there is no academic research on the weight of the boss. Therefore, according to the force characteristics of the boss, this paper divides the upper and lower areas (valve column and plate). The valve column with seal optimization and light weight is manufactured with a 3D printing additive, while the plate bearing and transferring the internal pressure load is manufactured by forging. Firstly, a two-dimensional axisymmetric simulation model of the sealing ring was established, and the effects of different compression rates on its seal performance were analyzed. Then, the size and position of the sealing groove were sampled, simulated, and optimized based on the Latin Hypercube method, and the reliability of the optimal seal structure was verified by experiments. Finally, the Solid Isotropic Material with Penalization (SIMP) topology method was used to optimize the weight of the boss with optimal sealing structure, and the reconstructed model was checked and analyzed. The results show that the weight of the optimized boss is reduced by 9.6%.

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Section: Experimental Verificationmentioning

confidence: 99%

Lightweight Type-IV Hydrogen Storage Vessel Boss Based on Optimal Sealing Structure

Shao,

Wang,

et al. 2024

WEVJ

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“…Recently, additive manufacturing has been explored for producing high-quality and reliable knuckles [21]. Kim et al [22] performed a finite element study of an additive manufacture steering knuckle for an electric vehicle.…”

Section: Introductionmentioning

confidence: 99%

Numerical Study of Reinforced Aluminum Composites for Steering Knuckles in Last-Mile Electric Vehicles

Santana,

Reyes-Osorio,

Orona-Hinojos

et al. 2024

WEVJ

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The steering knuckle is a critical component of the suspension and steering drive systems of electric vehicles. The electrification of last-mile vehicles presents a challenge in terms of cost, driving range and compensation of battery weight. This work presents a numerical methodology to evaluate 60XX series aluminum metal matrix composites (AMMCs) with reinforcement ceramic particles for steering knuckle components in medium heavy-duty last-mile cargo vehicles. The use of AMMCs provides lightweight knuckles with sufficient strength, stiffness and safety conditions for electrical vehicle cargo configurations. The numerical study includes three aluminum alloys, two AMMC alloys and an Al 6061-T6 alloy as reference materials. The medium-duty heavy vehicle class < 12 t, such as electrical vehicle cargo configurations, is considered for the numerical study (class 1–4). The maximum von Mises stress for class 4 AMMC alloys exceeds 350 MPa, limited by fracture toughness. The weight reduction is about 65% when compared with commercial cast iron. Moreover, Al 6061-T6 alloys exhibit stress values surpassing 300 MPa, constraining their suitability for heavier vehicles. The study proposes assessing the feasibility of implementing AMMC alloys in critical components like steering knuckles and suggests solutions to enhance conventional vehicle suspension systems and overcome associated challenges. It aims to serve as a lightweight design guide, offering insights into stress variations with differing load conditions across various cargo vehicles.

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“…Studies have shown that every 10% reduction in vehicle mass, fuel consumption can be reduced by 6%–8%, and exhaust emissions will be reduced by 5%–6%, which achieves the effect of energy saving and emission reduction and promotes the development of automobile lightweight to some extent. 1 At present, the main ways to achieve lightweight usually include structural optimization, 2–9 new materials, 10 and new processes. 11 Among them, Liang et al 2 optimized the structure of a gearbox under multiple load conditions, and the results showed that the mass of optimized gearbox was reduced by 7.6% compared with the initial model, the strength and stiffness were not weakened, and the first and second-order natural frequencies increased about 4.1% and 5.0%, respectively.…”

Section: Introductionmentioning

confidence: 99%

Lightweight design of a steering power cylinder bracket

Shen

2024

Advances in Mechanical Engineering

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As for lightweight design of components, the multi-body dynamics analysis was conducted on the hydraulic power steering system with double front axles, and the load spectrum of the Steering Power Cylinder Bracket (SPCB) under typical working conditions was worked out. Then, the nonlinear strength calculation and topology optimization analysis of the bracket were carried out. According to the optimization results, the eight schemes were designed and the optimal one was selected according to the results of static strength calculation. Then the optimal scheme was subject to the analysis on fatigue strength. Finally, it was verified that the optimized structure was effective by means of the vehicle durability test. The results show that the weight of the SPCB is reduced by about 2.53 kg (the lightweight ratio of 43.2%) when such performance as stiffness and strength are greatly improved compared with that of original scheme. The lightweight effect is obvious and the optimization process can guide the lightweight design of similar parts.

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Lightweight Design and Analysis of Steering Knuckle of Formula Student Car Using Topology Optimization Method

Cited by 6 publications

References 17 publications

Lightweight Type-IV Hydrogen Storage Vessel Boss Based on Optimal Sealing Structure

Lightweight Type-IV Hydrogen Storage Vessel Boss Based on Optimal Sealing Structure

Numerical Study of Reinforced Aluminum Composites for Steering Knuckles in Last-Mile Electric Vehicles

Lightweight design of a steering power cylinder bracket

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