Abstract. In this study, a systematic design process is carried out for the
design of the knuckle. A systematic method is proposed for the design and
analysis of a lightweight steering knuckle in an electric vehicle. In the
proposed approach, a finite element (FE) model of the knuckle is constructed
based on an inspection of the suspension and steering requirements of the
target vehicle and the results of a kinematic analysis. A two-stage topology
optimization method is then applied to refine the material distribution
within the FE model in such a way as to minimize the knuckle weight.
Finally, FE simulations are performed to evaluate the strength of the
knuckle under road impact conditions and to determine the fatigue life of
the knuckle for four ISO 8608 road classes (A–D). The results
show that the optimized knuckle has a weight of 3.64 kg (approximately
6.2 % lighter than the original knuckle of the same strength and material)
and achieves fatigue lives of 2.512×1011, 2.972×108, 5.598×103 and 2.432×101 cycles for
road classes A, B, C and D, respectively.