Design optimization of steering knuckle by adopting bionic design approach

Weight optimization plays vital role in performance improvement for an automobile. In vehicle, steering knuckle is one of critical components as it is subjected to millions of varying cyclic loads and it contributes to unsprung mass of vehicle. Therefore, steering knuckle of passenger vehicle is selected for this research work. The aim of this research work is to relate optimized shape of the part with bionic shape, which will give the optimum design. Topology optimization is used as a tool for getting optimum material layout with given space and boundary conditions. The objective function for topology optimization is to maximize stiffness with minimum mass constraints as 30%. The optimization is done by Altair INSPIRE software in which the part is imported as cad model with SG 500/7 as part material. The final surface modeling is done by Polyworks software package for parametric model and result of that modelling has been applied for the standard analysis of the part. The proposed design of the parts meets the strength and stiffness as per requirement. For physical prototype the part is manufactured by additive manufacturing using AlSi10Mg as a material and required properties for same material is also generated. New proposed design of the part shows that there is reduction in weight by 35%.