Design optimization and analysis of steering knuckle for FSAE EV racing cars

Abstract Steering knuckle is an important and complex component in both normal combustion cars and Formula SAE Electric Vehicle (FSAE EV) racing cars. This component is considered a crucial part that has a vital function in the automotive industry as it links the suspension to the wheel assemblies and is responsible for the precise steering, manoeuvrability, stability during turning, and general handling of the car. Its strategic location is evident as it might influence several aspects of a car’s steering system and thus, influencing the driving experience. Furthermore, this paper aimed to design steering knuckles that are specifically catered for FSAE EV racing cars and compare the outcomes with the current design of the steering knuckle. In this research, the ideation process of the steering knuckle designs for the FSAE EV racing cars involved brainstorming technique, taking into account the requirements and demands provided by the Taylor’s Racing Team (TRT). Through the utilization of SOLIDWORKS software, the 3D modelling process added detail to all the conceptual designs produced ensuring that they were clearly visualized. The ANSYS Simulation Software was used to conduct a Grid Independence Test (GIT) to determine the most suitable meshing size and shape, and the application of boundary conditions over the various parts of the steering knuckles at first. Then, ANSYS was also used to perform Static Structural Analysis to determine the stress distribution, total deformation and safety factor of steering knuckles designed for the FSAE EV racing car and the currently existing steering knuckle. All of the FSAE EV racing car steering knuckles were compared to the existing steering knuckle that was designed and provided by TRT to determine the enhancement in terms of stress distribution, total deformation, and safety factor. Therefore, the results have shown the importance of producing steering knuckles that are specifically catered for the FSAE EV racing car where the performance improvements were evident and ensured that the car could perform well on the track.