Optimization of Upright System of an Electric All-Terrain Vehicle (e-ATV) with Force Calculation and Finite Element Analysis

In an All-Terrain Vehicle design competition Knuckle is an important component which carries the complete wheel assembly and loads with itself. Loads in the wheels are directly transferred to the upright which can withstands itself with the proper design and force calculations. Forces are generated in the links of the upright and transferred to the chassis via tyre. The following study aims to design and manufacture knuckle by reducing the weight with the help of necessary force calculations on dynamic conditions in addition with Finite Element Analysis. Mass is the primary optimization in this analysis. We reduced up to 48.5% of mass from original design to get a final mass in rear upright and necessary force calculations for the front upright. The shape of the Upright is also well optimized according to compensate the suspension hardpoints. The front upright has Tie rod, caliper mounting, upper and lower arms. Lower the weight of the upright, higher the stability of the All-Terrain vehicle which contributes to the upsprung mass, impacts, and concluding remarks of the work.