Design and Optimization of Knuckle of an All-Terrain Vehicle

This study aims at designing, optimizing, and performing static analysis on front steering knuckle of a rear driven single seater. All-Terrain Vehicle (ATV). Weight reduction was carried while retaining satisfactory Factor of Safety (FOS) and structural strength. In the first step, the component was modeled using a licensed version of SOLIDWORKS^® 2016 and was initially analyzed with two different materials—aluminum and EN8. The knuckle was designed as per constraints set by suspension, steering, and wheel assemblies. In the next step, the analysis was carried out in licensed finite element software of ANSYS^® WORKBENCH™ by applying constraints and loads such as braking moment, cornering force, bump force, steering effort, lateral and longitudinal load transfer. Automated meshing with the sphere of influence at stress-prone areas was used for precise analysis. Second-order hex-dominant mesh type was employed for computation and convergence graph was plotted. The feasible material was chosen out of the two based on results and shape optimization was performed for two designs by adding material to sites that are subjected to higher stress than safety factor permits and removing material from low stress areas. Results were compared based on von Mises stress analysis and total deformation. A comparative study was carried out with analytical and simulation results and percentage of error was extracted from interpretation. A 3D printed model was also created in order to interpret the component’s physicality on the vehicle. Overall endorsement for the viability of design and fabricated component was provided by testing it on the vehicle.