Numerical Study of Reinforced Aluminum Composites for Steering Knuckles in Last-Mile Electric Vehicles

Abstract

The steering knuckle is a critical component of the suspension and steering drive systems of electric vehicles. The electrification of last-mile vehicles presents a challenge in terms of cost, driving range and compensation of battery weight. This work presents a numerical methodology to evaluate 60XX series aluminum metal matrix composites (AMMCs) with reinforcement ceramic particles for steering knuckle components in medium heavy-duty last-mile cargo vehicles. The use of AMMCs provides lightweight knuckles with sufficient strength, stiffness and safety conditions for electrical vehicle cargo configurations. The numerical study includes three aluminum alloys, two AMMC alloys and an Al 6061-T6 alloy as reference materials. The medium-duty heavy vehicle class < 12 t, such as electrical vehicle cargo configurations, is considered for the numerical study (class 1–4). The maximum von Mises stress for class 4 AMMC alloys exceeds 350 MPa, limited by fracture toughness. The weight reduction is about 65% when compared with commercial cast iron. Moreover, Al 6061-T6 alloys exhibit stress values surpassing 300 MPa, constraining their suitability for heavier vehicles. The study proposes assessing the feasibility of implementing AMMC alloys in critical components like steering knuckles and suggests solutions to enhance conventional vehicle suspension systems and overcome associated challenges. It aims to serve as a lightweight design guide, offering insights into stress variations with differing load conditions across various cargo vehicles.

Development of the Low-Pressure Die Casting Process for an Aluminium Alloy Part

“…In Table 3, the process conditions implemented during the simulation process, including the pouring temperature, initial die temperature, heat transfer coefficients between volumes, and boundary conditions considered are presented. Definition of the temperature relationships between the simulation elements and the casting environment (free surface inside the die cavity and the contact of the die with the exterior) 1 Heat transfer condition present in the ProCAST ® library.…”

“…The steering knuckle is a critical component within a vehicle’s suspension system, serving multiple essential functions. Within the automotive industry, steering knuckles require attributes such as exceptional mechanical strength, unyielding structural rigidity, and a propensity for lightweight construction [ 1 , 2 , 3 ]. This need arises from the mechanics of steering, whereupon the actuation of the steering wheel by drivers induces tensile forces upon one portion of the steering knuckle and compressive forces upon the other.…”

“…1 EN 1706:2020-Aluminium and aluminium alloys-Castings-Chemical composition and mechanical properties.…”