Structural Optimization of a Knuckle with Consideration of Stiffness and Durability Requirements

The automobile's knuckle is connected to the parts of the steering system and the suspension system and it is used for adjusting the direction of a rotation through its attachment to the wheel. This study changes the existing material made of GCD45 to Al6082M and recommends the lightweight design of the knuckle as the optimal design technique to be installed in small cars. Six shape design variables were selected for the optimization of the knuckle and the criteria relevant to stiffness and durability were considered as the design requirements during the optimization process. The metamodel-based optimization method that uses the kriging interpolation method as the optimization technique was applied. The result shows that all constraints for stiffness and durability are satisfied using A16082M, while reducing the weight of the knuckle by 60% compared to that of the existing GCD450.