Finite Element Shape Optimization of a Steering Knuckle for a Heavy Truck–A Case Study

A case study of the application of shape optimization techniques to reduce the weight of a steering knuckle of a heavy truck suspension has been presented. Design analysts, who work with finite element shape optimization, face a daunting task while handling such complicated parts - uneven shape, multiple load cases and element distortions during shape optimization, etc. A baseline analysis confirmed that the knuckle was overweight. A shape optimization analysis was undertaken to bring down its weight and at the same time keep the stresses within design limits. A numerical interpolation method has been used to generate shape vectors. The weight of the knuckle was brought down by 12.7% and the final design was verified using II order solid finite elements.