Finite Element Analysis of In-Service Loading on Hub Steering Knuckles: A Comparison of A356.0-T6 and Grey Cast Iron
Journal Title: Precision Mechanics & Digital Fabrication - Year 2025, Vol 2, Issue 1
Abstract
This study investigates the structural response of a hub steering knuckle from a Toyota Camry LE under typical in-service loading conditions, with a focus on material performance comparison. Aluminium alloy A356.0-T6 and grey cast iron were selected as candidate materials for the analysis. A three-dimensional (3D) model of the hub steering knuckle was generated using SolidWorks 2018, while static structural simulations were conducted with ANSYS Workbench R15.0 (2019 version). The factor of safety (FOS) was varied between 2.293 and 15 to account for the diverse operational scenarios. The applied loading conditions were derived from the cumulative forces acting on the four tyres of the vehicle, with a total force of 3938.715 N in the Z-direction. The steering moment was calculated to be 5400 N·mm at a perpendicular distance of 108 mm, while the braking force amounted to 3964.63 N·mm, with a corresponding braking moment of 277,524.73 N·mm, all determined using standard analytical formulas. A solid mesh type was employed for the finite element analysis (FEA), with a blended curvature-based meshing technique applied. The results of the analysis showed that, for A356.0-T6, the maximum equivalent Von Mises stress (VMS), maximum equivalent elastic strain, maximum principal stress, and maximum shear stress were 36.079 MPa, 0.00018393 mm/mm, 44.587 MPa, and 19.871 MPa, respectively. In comparison, grey cast iron exhibited values of 24.016 MPa, 0.00013104 mm/mm, 41.214 MPa, and 18.625 MPa, respectively. The maximum directional deformations along the Z-axis for A356.0-T6 and grey cast iron were 0.010135 mm and 0.007275 mm, respectively. The maximum total deformations were recorded at 0.069036 mm and 0.048725 mm for A356.0-T6 and grey cast iron, respectively. These findings suggest that both materials are suitable for use in hub steering knuckles, with grey cast iron being preferable when impact resistance is a priority, whereas A356.0-T6 is more suitable for applications requiring lightweight and corrosion resistance. The results contribute to the understanding of material selection for automotive components, considering both mechanical performance and operational demands.
Authors and Affiliations
Aniekan Essienubong Ikpe, Jephtar Uviefovwe Ohwoekevwo, Imoh Ime Ekanem
Keywords
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- EP ID EP767843
- DOI https://doi.org/10.56578/pmdf020102
- Views 7
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