Lightweight co-design solution for aluminum steering knuckle based on casting process

As a core safety component of suspension systems, automotive steering knuckle faces the challenge of material, structure and process optimization under the trend of lightweight. This paper proposes a multi-objective optimization framework of “simulation-materials-structure-process”. Firstly, a finite element model is constructed based on CAE, combined with ADAMS vehicle dynamics and Ansys static simulation to extract the stress and deformation data under the key working conditions. Through material optimization, the part is replaced with a new type of aluminum alloy and the strength performance is verified. The material layout is designed for multiple working conditions by using the Ansys topology optimization module. After the design and post-processing with process constraints, the structure is optimized to reduce the mass and volume by 4.2% and increase the safety coefficient of extreme working conditions by 0.0388. Finally, the process parameters are optimized by ProCAST low-pressure casting simulation to reduce the rate of shrinkage and loosening, and the spacing of the secondary branched crystals. This technology route establishes a systematic solution to achieve the goal of aluminum alloy steering knuckle lightweight, but also to ensure the quality and reliability of the casting, in which the topology optimization of weight reduction and casting defects control and other key technology breakthroughs, providing an important technical support for the engineering application, and promoting the continuous development of automotive parts and components to the direction of high efficiency and lightweight.