Paper Details

ABSTRACT

This study was aimed at developing general procedures for fatigue analysis and optimization of safety-critical automotive components with manufacturing considerations. A literature survey was conducted, specimen and component tests were performed, and optimization evaluations of similar components produced by different manufacturing material were made to achieve the objectives. The typical example component chosen was a vehicle steering knuckle made of six competing materials and manufacturing processes including forged steel, cast aluminum and cast iron. In the literature survey, manufacturing processes were studied and compared with focus on mechanical behavior. The methods used in the literature for fatigue life evaluation and prediction of automotive components, as well as for optimization studies with respect to geometry, material and manufacturing aspects were also reviewed. Comparisons of materials and properties, along with components’ behaviors were made for competing material and manufacturing processes. In terms of structural performance and durability, based on both material testing and component evaluation, forged steel was found superior to cast iron which in turn was found superior to cast aluminum.