A Novel Approach for Generative Design and Performance Analysis of an Additively Manufactured Formula Vehicle Knuckle

Generative Design is 3D CAD technique that uses AI to autonomously create optimal and productive design. Unlike regular designs, generative design applies algorithms to parameters that generate several possible design variations to review and choose from. The important and necessary factor of a formula vehicle is components that show high strength with light weight exhibiting higher performance. The un-sprung weight reduction is the most prevalent consideration while designing a formula vehicle. Our proposed study is focused to design and develop a formula vehicle knuckle through generative design method. Considering the manufacturing complications, continuous Fused Filament Fabrication (FFF) with Onyx – Carbon Fibre composite is contemplated with all the test samples and response dataset taken into consideration. The primary work involves the designing of steering knuckle with the help of computation software. Design and optimization are performed under varying loading conditions for obtaining deformation and von-misses stress responses. On exposing to higher and multiple loads acting conditions, the deformation and von-misses stress is in considerable level when compared to conventional knuckle. Based on the outcome of this study, it is revealed that the generative design knuckle has light weight, without compromising strength. The developed generative design can be recommended to replace the conventional knuckle in formula vehicle for improved efficiency by reducing the un-sprung weight of the vehicle. The customized design knuckle will have better on-track performance and steer ability for the formula vehicle.