Design Optimization of Formula Student Car Steering Knuckle

Abstract

The crucial need for capable vehicles to operate at their maximal performance has urged student teams to discover specific portions to alter, especially in ensuring a lightweight condition. For this purpose, designers have considered the redesigning of spot areas such as the knuckle and the certification of new designs with improved capability and reliability. The objective of this project is to replace the existing knuckle system of a formula student car with a new optimized design which demonstrates greater capability in terms of durability, lightweight feature, uniformity of applied force, and stability, particularly in the cornering performance during a race. Therefore, this project ultimately aims to develop a lightweight knuckle for a KKBD formula student car, applicable to withstand various loads from multiple sources. In addition, the study proposed competent material selection and manufacturing procedures for the knuckle component design. Validation of material selection was carried out via HYPER MESH software to discover the design durability by applying various load paths. The simulation results revealed the improvements of the new knuckle design in comparison to the existing design, wherein the load and stress distribution was more ideal. On the other hand, the stress and load distribution of existing design was more focused on the welding area and demonstrates fluctuation with alternating applied loads which may contribute to fracture during a race performance.