Published by : International Journal of Engineering Research & Technology (IJERT)

http://www.ijert.org ISSN: 2278-0181

Vol. 5 Issue 04, April-2016

Design and Analysis of Steering Knuckle

Component
Sanjay Yadav1, Ravi Kumar Mishra1, Varish Ansari1, Shyam Bihari Lal2
1
Student,2 Assistant Professor,
Department of Mechanical Engineering,
Buddha Institute of Technology, Gorakhpur, U.P. India

Abstract – The Steering Knuckle component is the most

important part of vehicle which is connected to front wheel with
the help of suspension system, wheel hub and these are also
connected to steering system and brake to the chassis. The
Steering Knuckle component provides motion to desire
2
directions with the help of steering system. It undergoes various
types of varying load under different conditions. In Automobile
industry low fuel consumption and light weight are the two
main demands for the vehicle because the lighter steering
3
knuckle resulting greater power and less vibration because of
inertia is less. In this Paper we have done static analysis of
1
steering knuckle component. The design of Steering Knuckle
component is done with the help of Computer Aided
Engineering (CAE). Steering Knuckle model is prepare in
Creo(Pro-E) 2.0 and the static analysis is done in ANSYS
WORKBENCH15.0 by constraining the steering knuckle and 4
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 5 5
compare it, made from two material i.e. Cast Iron and Mild
Steel which is recently using, and Forge Steel EN 47 which is
suggested material. This result is verified by comparing with
analytical calculations. Considering these results, model is Fig 1.Steering Knuckle
modified.
The part of steering knuckle component are given below:
Keywords –Steering knuckle component, Static Analysis, 1. Suspension Mounting Upper Arm/Strut Mount
Material,and ANSYS WORKBENCH 15.0. 2. Tie Rod Mounting / Steering Arm
3. Lower Ball Joint /Suspension Mounting Lower Arm
I. INTRODUCTION 4. Ball Bearing Location / Stub Hole
5. Brake Caliper Mounting
Steering knuckle is the critical component of the The shape and size of steering knuckle component
vehicle which is linked with suspension system. It allows depends upon the vehicle weight because vertical load of the
steering arm to turn the front wheel and it also supports the vehicle is directly act on it and hence the steering knuckle
vertical weight of the vehicle. The steering knuckle is the component subjected to power thrust from tie rod to the stub
connection between stub axle, tie rod and axle housing with axle and hence it must be strong and inflexible in nature.
the help of using king pin, and these are also connected to The steering knuckle in the automobile industry can be made
the suspension system [6]. In this, wheel hub is fixed with either by forging or from casting. However, castings have
steering knuckle with the help of bearing. The main function blown-holes which are injurious from fatigue and durability
of steering knuckle is to convert linear motion of the tie rod points of view. The fact that forgings produce blow-hole free
into the angular motion of the stub axle [5]. In the and good parts give them an advantage over cast parts. Due
automobile industry, the requirement of properties of to large volume production of steering knuckle component, it
steering knuckle is that it must be strong, inflexible and light is only logical that optimization of the steering knuckle for
as well as possible. When steering is turn by drivers, half its volume orweight should be result in large-scale saving.
portion of the steering knuckle component is subjected to The reduction of inertia load, torsional load, vehicle weight
tensile load and another half portion of steering knuckle will improve the vehicle performance and fuel economy.
component is subjected to compressive load and due to this
rotation of wheel, steering knuckle is subjected to torsional
load.

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http://www.ijert.org ISSN: 2278-0181
Vol. 5 Issue 04, April-2016

II. METHODOLOGY which the size should be mainly depends on suspension

system. The previous steering knuckle was made by Mild
This study has been has been followed in two parts. First
Steel (yield strength 250MPa) and the mass is about 3.7kg.
part of this study includes modeling of steering knuckles
And Forge Steel which is suggested material which yield
component and analysis of stresses under actual load
strength is 350MPa.In general, a steering knuckle has three
conditions. CAD models of steering knuckle were developed
connections on the body part; connection to the tie rod,
in 3D modeling software, such as Creo (Pro-E) 2.0. Whilethe
suspension upper arm and suspension lower arm. Therefore
second part is of the models were then obtained and
the design needs to be stressed on these three connections, as
compared using finite element analysis (FEA) via ANSYS
well as one side of connectors where brake caliper mounting
WORKBENCH Simulation software.
is attached.
Approach of this study is shown in Fig -2.

Initiate and Evaluate Current Design

Review and Analyze Current Design

3D Modeling
Creo (Pro-e) 2.0

FEA Analysis
ANSYS WORKBENCH 15.0. ISOMETRIC VIEW
FRONT VIEW

NO
Evaluate
Designing

YES

Again Analyses and Optimized

Compare With Initial Model Fig. 3 Projection View of Design Modeling

IV. DESIGN OF STEERING KNUCKLE

Final Result and Finish (A) Calculation of Load

Fig.2 Design Methodology Process Flowchart i). Axial Loads

III. DESIGN MODELING There are two axial load acting on the steering knuckle
CAD model of steering knuckle component was made in such as tensile load and compressive load[5]. The stress due
3D modeling software Creo (Pro-E) 2.0. It consists of Stub- SIDE VIEW TOP VIEW
to this load can be findout using the following formula,
hole Brake Caliper mounting points, Steering tie-rod
mounting, Suspension upper arm mounting and Suspension Tensile Load (𝑃𝑡 )= Tensile stress × Area
lower arm mounting. Steering knuckle component design
mainly depends on suspension system geometry and steering Compressive Load (𝑃𝑐 ) = Compressive stress ×Area
geometry. The design processes were started with
preliminary study on the current steering knuckle component
used for the previous including investigating the existing
knuckle design especially from the published design of
Formula Society of Automotive Engineering (SAE)[4]. The
design also needs to follow the criteria and regulations,

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Vol. 5 Issue 04, April-2016

ii). Inertia Load LOADING CONDITION

This load act on Steering Knuckle due to the inertia Braking Force 1.5mg
of the moving parts[5] .The inertia load can be find out Lateral Force 1.5mg
using the following formula, Steering Force 45-50N
Force on knuckle hub in X- axis 3mg
𝑅
Inertia Load (𝐹𝑎 ) = 𝜔2 R[𝑐𝑜𝑠 𝜃 + 𝑐𝑜𝑠(2𝜃)] Force on knuckle hub in Y- axis 3mg
𝐿
Force on knuckle hub in Z- axis 1mg
iii). Bending Load
This load acts on the steering knuckle due to the Table 1.Loading Condition on Steering Knuckle
weight of the vehicle and this tends to bend the steering
If the knuckle is design for the vehicle of 1240kg weight
knuckle outward away from the centerline [5].Total inertia
.Thus braking force acting on it produced moment. This
bending load is given by,
calculated as,
𝜌𝐴𝑡 𝐿𝑠𝑖𝑛(𝜃+∅)
Bending Load (𝐹𝑏 ) = N Braking force = 1.5mg
2
= 1.5×310×9.81
(B) Calculation of Stresses
= 4561.65 N
i). Stress Due to Axial Loads
For calculation braking force acting on one wheel
The force of resistance per unit area, offered by a body i.e.1240/4=310kg for one wheel and perpendicular distance
against deformation is known as stress. is 94mmconsidered.
This is given by, Moment = Braking force × perpendicular distance
𝑃
Stress (σ) = = 4561.65×94
𝐴
= 428795.1 N-mm (for one wheel)
ii). Stress due to Inertia bending force
This moment is acting on steering knuckle where
Inertia bending load sets up a stress which would be
breakcaliper is mounted [6].Since all loads act in X, Y and Z
tensile on one side of the knuckle and compressive on
direction are perpendicular to each other as shown in fig 3.
another side and that these stress change sign each half
revolution [5].The bending moment at any section ‘X’ m
from the small end is given by,
𝑥 𝑥2
M = 𝑎 [1 − ]
𝐿2
The Stress is calculated by,

M
𝜎𝑏 =
Z

I
M=
2.5×𝑡

I = 419 ×t4

(C) LoadingCondition on Knuckle

Fig 4. Direction of Forces and Moments
For the calculation of load acting on steering knuckle
component, the required loading condition which are Thus the resultant force is given by,
follows:
F = √𝑋 2 + 𝑌 2 + 𝑍 2

X=Y=3mg =3×310×9.81= 9123.3 N

Z=1mg = 1×310×9.81= 3441.1 N
F = √(9123.3)2 + (9123.3)2 + (3041.1)2

F = 13255.84 N

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V. MATERIAL SELECTION

The steering knuckle is made by different type of

materials such as Cast iron, Mild steel and Aluminum. Cast
Iron and Mild steel have a good strength but it contributes
more weight to the vehicle. Forged steels are the most
demanding materials for the steering knuckle in future. Due
to the low weight of the materials fuel consumption can be
stretch to the optimum level [1]. In this paper Forge steel EN
47 is used as it offers a better strength and lightweight for the
steering knuckle component. Forge Steel materials are
generally used where high tensile strength and toughness is
required thus the Forge Steel EN 47 materials are suited for
the steering knuckle component. Due to this low weight of
materials, it can decrease the fuel consumption and it have
low density and sufficient yield strength. The mechanical
physical and chemical properties of Forge Steel materials are
given below: Fig. 5. Meshing Model

PHYSICAL PROPERTIES
VII. ANALYSIS
QUANTITY VALUE UNIT The analysis of steering knuckle component is done
in ANSYS Workbench 15.0. The required load of steering
Density 7.7 g/cm3 knuckle component was determine from various research
MECHANICAL PROPERTIES paper. According to papers we assume average weight of
vehicles is 1240 kg. The weight are directly acted on all the
QUANTITY VALUE UNIT four knuckle. Thus the weight of vehicles acted on one wheel
Tensile strength, Ultimate 650 Pa is 310 kg. Thus the average weight of vehicles acted on each
Tensile Strength, yield 350 Pa wheel is 310 × 9.81 = 3041.1 N. There are various force act
Young’s Modulus 200 GPa
Poisson Ratio 0.3 ─
on this such as braking force, moment, lateral force, steering
Table 2. Mechanical And Physical properties of force as well as loads on knuckle hub in X, Y and Z-
Forge SteelEN 47 direction. The various analysis results are shown in figures
which are given below:
ELEMENT % WIEGHT
Carbon, C 0.45- 0.55
Manganese, Mn 0.50 – 0.80
Silicon, Si 0.05 Max
Chromium, Cr 0.80 – 1.20
Sulphur, S 0.05 Max
Phosphorous, P 0.05 Max
Table 3. Chemical Composition of Forge Steel EN 47

VI. MESHING THE COMPONENT

CAD Model of steering knuckle component is
produced in 3D modeling software such as Creo (Pro-E) 2.0.
This CAD model is imported into an ANSYS
WORKBENCH 15.0. In this, it is not necessary to set a mesh
control because these have default mesh control. There are
we can used smart mesh control to produce the fine mesh Fig. 6. Total Deformation (Forge Steel EN 47)
generation.

NODES 5384
ELEMENTS 2705

Table 4. Nodes and Elements of Model

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Fig. 9Maximum Principal Stress (Forge Steel EN 47)

Fig. 7 Directional Deformation (Forge Steel EN 47)

Fig. 8Maximum Shear Stress (Forge Steel EN 47) Fig. 10 Equivalent “Von-Mises” Stress (Forge Steel EN 47)

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Parameter Initial Final

Material(Mild Material(Forge
Steel) Steel EN47)
Total Deformation 0.854mm 0.626mm

Directional 0.595mm 0.896mm

Deformation
Maximum Stress 109.34MPa 112.25MPa
(Von-Mises)

Maximum shear 60.347 MPa 62.11 MPa

stress

Maximum 70.111 MPa 70.295 MPa

Principal Stress

MASS
Initial Final % Reduction
Material(Mild Material(Forge
Steel) Steel EN47)
3.72kg 3.51kg 5.64 %

Table 5. Analysis Result of Knuckle Component

IX. CONCLUSION
The steering knuckle component has been
modelled using Creo (Pro-E) 2.0 and analyzed using ANSYS
Fig.11 Equivalent Elastic Strain (Forge Steel EN 47) WORKBENCH15.0. The various parameters such as total
deformation, directional deformation, Maximum principal
stress, And Maximum Shear Stressare completely analyzed.
This paper represent that the areas where the stress
concentration is maximum due to the applied load. The study
of steering knuckle component gives the small change in
directional deformation and 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
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used.The optimized value of result is shown in Table 5.

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Vol. 5 Issue 04, April-2016

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