Topology Optimization of Steering Knuckle using Aluminium-Carbon Fiber Hybrid Material

The steering knuckle is the most vital element of a car; it is associated with the suspension system, front wheel, wheel hub, as well as chassis through the steering and braking systems. It travels along the driver's chosen paths with the help of the steering system. Under different conditions, it encounters a variety of loads. By implementing the steering knuckle's topology optimisation and moving from the present production material to a hybrid material, the major focus of this project is to lower the weight of a steering knuckle. In the automotive manufacturing and industrial sectors, the future car must be lightweight and fuel-efficient. This is due to a lighter steering knuckle generates higher power and less vibration because there is less inertia when driving. 5% carbon fibre and 95% aluminium (5XXX series) make up the hybrid material's makeup. Using the IGS format, the steering knuckle model's design was imported from SOLIDWORKS 2020 to ANSYS Workbench 18.1 for static analysis. The static analysis result and the topology optimization, it is found that about 86.5% weight reduction is achieved as compared to grey cast iron.