Finite Element Analysis and weight Optimization of Knuckle joint for different materials by using CAE Tools

The current study involved the analysis of a knuckle joint using finite elements. A mechanical joint with two intersecting cylindrical rods whose axes are in the same plane is called a knuckle joint. Knuckle joint should be designed and manufactured in such a way that it can sustain more load without failure. The objective of the present study is to study knuckle joints made of different materials like aluminum, stainless steel, structural steel, magnesium, and gray cast iron using CAE tools. The CAD model of knuckle joint is made in CATIA V5 R20. The finite element analysis of this CAD model using ANSYS 15 has been carried out to investigate maximum stress and deformation. The CAE results compared with the analytical results using conventional approach. The CAE results have been found close to the analytical results, thus validating the model. The knuckle joint of aluminum is found to have highest factor of safety (1.641) at 50 KN load and is the most the most suitable material for knuckle joint. Weight of vehicle plays an important role in overall performance and fuel efficiency of vehicle. Knuckle joint is a part of vehicle. Hence weight optimization of knuckle joint made of aluminum has been performed using ANSYS 15 and it is observed that weight of knuckle joint made of aluminum can be reduced by 5.08% for 50 KN loading condition.