Overview |
Front Knuckle Package Overview
2016 Front knuckle package
The front knuckle package is a project which has constantly evolved in my time as suspension design lead. The system has benefited from constant iteration and improvements to reduce weight and improve strength. The spindle, hub, and knuckle take some of the highest loads on the car, and simpler designs allow for constant in-house iterations to be made. This shortened the design cycle and improved the overall quality of the design. This process led to the first custom front hubs and brake rotors on a Northeastern vehicle.
Sample 1 |
Front Spindle Plasticity Modeling
•Problem:
–After a significant impact during the 2014 season, the front spindle deflected approximately .03” •Goal: –To calculate the force required to create this deformation and use it to inform the design of the spindle, hub, and knuckle •Solution: –By using Von Mises Plasticity elements, inputting a stress strain curve for the 4140 spindle into SolidWorks Simulation, and approximating wheel impact angle, the force was calculated to approximately be a 5.5g wheel impact –New spindle material chosen to be 4150 Q&T which increases strength without increasing hardness |
Front spindle deflection (rotor and knuckle should be parallel)
|
Sample 2 |
Front Hub Design
•Problem:
- Stock wheel hubs were heavy and severely limited the design freedom in knuckle packaging. Goal: - By using the forces determined from the plasticity FEA model and maintaining comparable factors of safety, a new hub was to be designed to be lighter and give better clearance for brake caliper integration. Solution: - 2015 Hub was designed to use 7075 with a minimum factor of safety of 1.7 and a .5 lb weight reduction - For validation purposes, 6061 hubs were machined and the impact was replicated. The hub was inspected for deflection to validate loading scenario. Failures were observed in 6061 components and additional design changes and better load approximations were made |
Stock hub (left) and first custom hub (right)
|