GENERATIVE DESIGN APPROACH AND PERFORMANCE ANALYSIS OF VEHICLE KNUCKLE

MECHANICAL ENGINEERING

The design and performance of steering knuckles in high-performance automotive applications, such as Formula racing, play a critical role in vehicle dynamics. Traditional manufacturing methods often fail to optimize structural efficiency, weight, and durability, impacting overall vehicle performance. This project explores the potential of Additive Manufacturing (AM) and Generative Design techniques to enhance the knuckle's design by focusing on critical factors such as weight reduction, durability, and performance under high-speed conditions. Through the use of advanced composite materials like Carbon Fiber and PEEK polymers, combined with a generative design approach, this study aims to create a lightweight yet strong knuckle, offering superior strength-to-weight ratios compared to traditional materials like aluminium and cast iron. The proposed methodology involves the design, simulation, and optimization of knuckle components using SolidWorks for modelling and ANSYS for structural analysis. The results of this study demonstrate that by integrating generative design and AM, substantial improvements can be achieved in both the performance and manufacturability of automotive knuckles, leading to enhanced vehicle efficiency and alignment with sustainability goals. This research contributes to the advancement of innovative manufacturing techniques in motorsports and automotive engineering, paving the way for future applications in lightweight structural components

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