Design and Manufacturing of Knuckle Hub for Formula Student F1 Car

– The steering knuckle is a vital part of a vehicle’s suspension and steering system, linking the wheel hub to the suspension arms and steering linkage. In the context of student formula cars, weight reduction and structural strength are crucial design objectives. This study aims to design a lightweight and durable steering knuckle using high-strength materials while maintaining performance and safety. A 3D model of the knuckle was created in SolidWorks 2022, and static structural analysis was performed using ANSYS Student Version 2022 R2. The knuckle was subjected to realistic loads including vertical vehicle weight, longitudinal braking forces, and steering reactions. Among various materials studied—Aluminum 6061-T6 and Mild Steel A36, Aluminum 7075-T6 was selected due to its high strength-to-weight ratio and fatigue resistance. The simulation results confirmed that the component meets structural and safety requirements under expected loading conditions. The final design achieves a good balance between weight and durability, making it a suitable choice for high-performance student racing applications.