Structural strength analysis of a tourist minicar knuckle using finite element analysis

Agung Fauzi Hanafi; Mega Lazuardi Umar; I Gusti Ngurah Agung Satria Prasetya Dharma Yudha; Ansor Salim Siregar

doi:10.30811/jpl.v24i1.8194

Structural strength analysis of a tourist minicar knuckle using finite element analysis

Agung Fauzi Hanafi, Mega Lazuardi Umar, I Gusti Ngurah Agung Satria Prasetya Dharma Yudha, Ansor Salim Siregar

Abstract

The design of components for vehicles used in tourist areas must be efficient, safe, and economical. The steering knuckle is a vital component in the vehicle's suspension and steering systems, playing a crucial role in transferring loads, connecting the wheel to the steering mechanism, and supporting braking components. This research aims to design, analyze, and fabricate a steering knuckle for a mini tourist car with a total mass of 300 kg using plain carbon steel. The design and strength analysis were evaluated using the open-source Finite Element Analysis (FEA) software PrePoMax to investigate stress distribution, deformation, and the factor of safety. The FEA results showed a maximum Von Mises stress of 86.27 MPa, well below the material's yield strength, a maximum deformation of 0.126 mm, and a minimum safety factor of 2.72, confirming a robust design. The component was designed to accommodate a 30204 tapered roller bearing. The fabrication process, encompassing cutting, machining, and welding, successfully produced a functional prototype validated through direct installation and load testing on the vehicle. This study confirms that plain carbon steel is a reliable and economical material for structural components in lightweight vehicle applications and provides a pragmatic engineering framework for developing cost-effective automotive components.

Keywords

Steering Knuckle; Carbon Steel; Open-Source; Fabrication; Tourist Minicar

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DOI: http://dx.doi.org/10.30811/jpl.v24i1.8194