The objective is to transform the design of the Cast Iron Steering Knuckle into one made from Aluminum material. This conversion from Cast Iron to Aluminum is intended to reduce weight, consequently enhancing vehicle performance through improved mass efficiency.


Aluminum exhibits lower strength in comparison to Cast Iron. The challenge involves achieving strength performance by enhancing cross-sections. Matching the strength performance needs to be accomplished while adhering to package space and clearance requirements.

Design process:

The design process encompasses the following stages:

For CAE load generation:

● Gross Vehicle Weight (GVW)
● Front and Rear Axle weights
● Center of Gravity specifics (height from ground) at GVW state.
● Wheelbase.
● Tyre contact patch distance (from Wheel center to ground impact point for Largest Tyre in Z-direction)
● Inclusion of attachment parts from CAD data for CAE.

For clearance assessment:

● Assembly package evaluation at varied articulated positions to verify clearance under all articulations
● Tyre CAD (Largest Tyre configuration)

Value delivered:

Developed an Aluminum (Al) design weighing 6.5kg, derived from the Cast Iron (CI) design weighing 13.95kg. Achieved a significant mass reduction of 47%. The Aluminum design adheres to all manufacturing requirements including both casting and machining. It effectively meets clearance, packaging, and assembly requirements, while retaining the identical interface as the Cast Iron design.


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