This document presents a project on the design and analysis of a knuckle and hub for an FSAE race car. It discusses sponsoring companies, introducing the purpose and problem definition. It outlines the methodology, which includes CAD modeling and ANSYS analysis. Expected outcomes are a lighter knuckle weighing 750g and 800g, and hub weighing 1.5kg. Material selection and design calculations are presented. Results show maximum stresses below limits. The project aims to reduce weight while maintaining stiffness for a better performance to weight ratio.

1. A
Project Presentation
On
DESIGN AND ANALYSIS OF KNUCKLE AND HUB OF FSAE RACE CAR
submitted to
University of Mumbai
in partial fulfillment of the requirement for the degree of
Bachelor of Engineering (Mechanical)
submitted by
1. MR. PISAT SANGRAM K. 2. MR. SHINDE ROHAN R.
3. MR. PHULE ADITYA S.
Under the Guidance of
PROF. JAVIR ARUN V.
DEPARTMENT OF MECHANICAL ENGINEERING,
RAJENDRA MANE COLLEGE OF ENGINEERING & TECHNOLOGY, AMBAV (DEVRUKH)
PIN-415804, 2015-16

2. Sponsoring Company Details
• Name of the company: ELENO INSTITUTE,
PUNE
• Establishment year: 2014
• Type of work completed at company: Analysis
of CAD model.
• No. of days/hours engaged at company: 3 days
• Contact person/s: Mr. Nachiket Phadke
• Designation: Founder
• Department: Design

3. Sponsoring Company Details
• Name of the company: UNITY INDUSTRIES,
KARAD
• Establishment year: 2005
• Type of work completed at company: Fabrication
• No. of days/hours engaged at company: 10 days
• Contact person/s: Mr. Ramdas Dattatreya
Shingare
• Designation: Proprietor
• Department: Sales and marketing.

4. INTRODUCTION
• The purpose of this project is to design and manufacture the front and the
rear wheel upright assembly for use of formula SAE car.
• Central component of suspension system.
• All suspension components including the control arms, steering arms,
springs, shock absorbers, brake, tires and in case of the rear upright the
axles are connected to uprights.
Problem Definition:
• Use of conventional knuckle and hub will increase the weight of vehicle.
• Weight reduction criteria for FSAE car.
• Design of knuckle and hub for proper stiffness as well as low weight.

5. METHODOLOGY
• Review of current knuckle and hub assemblies available in
market .
• Optimum material selection with cost of material and also
properties of materials
• 3D CAD modeling of uprights system using SOLIDWORKS.
• Analysis on design of CAD model of knuckle and hub using
ANSYS.
• Manufacturing of analyzed upright system using VMC.

6. EXPECTED OUTCOME
• To produce a lighter design of hub and knuckle and not sacrifice
performance in stiffness, thereby contributing to making FSAE car better.
• Expected weight of front knuckle would be 750 grams and that of rear
knuckles would be 800 grams.
• Expected weight of hub would be 1.5 kg.

7. REVIEW OF LITERATURE
Sr.
No.
Description Outcomes/Results
1 Final report, OLD DOMINION
university SAE team
Load transfer, breaking force
and torque calculation.
2 B. Bolles, Advanced Race Car Chassis
Technology
Braking force calculation
3 Studies on AL6061-SiC and AL7075-
Al2O3 Metal matrix composites,
Journal of minerals and material
characterization and engineering.
Selection of material for
manufacturing of knuckle and
hub.
4 P. G. Sturgess, Engineering Inspiration Design consideration and
constraints

8. OBJECTIVES
• Light weight to maintain good performance to weight ratio of race car.
• Optimum stiffness to ensure low system compliance and maintaining
designed geometry.
• Ease of maintenance for enhancing serviceability and setup
repeatability.
• The purpose of this project is to design and manufacture components in
house to reduce turnaround time and outside dependability.

9. DESIGN CALCULATIONS
•The load transfer on to the upright due to turning would
increase this load to 1500 Newton.
Weight= 280 kg
Acceleration= 1.5 * 9.81
CG height= 37.5 cm
Track width= 137.16 cm
Ans: Design load transfer is 1377.95 Newton.

10. DESIGN CALCULATIONS
• Braking force= weight * deceleration
• Braking force= 280 * 1.5 * 9.81= 3237.3 N
• Bearing used- NTN single row bearing
• For front knuckle- inner diameter is 40 mm and outer
diameter is 62 mm.
• For rear knuckle, Inner diameter is 60 mm and outer
diameter is 85 mm.

11. MATERIAL SELECTION
Properties Al6061 Al7075
Elastic Modulus (GPa) 70-80 70-80
Density (g/cc) 2.7 2.81
Poisson’s Ratio 0.33 0.33
Hardness (HB500) 30 60
Tensile strength (Mpa) 115 115

12. Components Wt. %
Al 87.12-91.4
Cr 0.18-0.28
Cu 1.22-2
Fe Max 0.5
Mg 2.1-2.9
Mn Max 0.3
Si Max 0.4
Ti Max 0.2
Zn 5.1-6.1
MatWeb : Material property Data
Aluminium Alloys 7075-T6;7075-T651

13. USES OF AL 7075 – T6
• 7000 series alloys such as 7075 are often used in
transport applications, including marine, automotive and
aviation, due to their high strength-to-density ratio.
• 7075 is used in the manufacture of M16 rifles for the
American military.
• Due to its high strength, low density, thermal properties,
and its ability to be highly polished, 7075 is widely used
in mould tool manufacture.
• Rock climbing equipment, bicycle components, in line
skating-frames and hang glider airframes are commonly
made from 7075 aluminium alloy.

14. 3D CAD MODEL OF PROJECT SET-UP
Fig. 1- Front knuckle Fig. 2- Rear knuckle
Fig. 3 Front hub Fig. 4- Rear Hub
1 2
3 4

15. KNUCKLE NOMENCLATURE
Calliper
Mounts
Dia. 85 mm
Provision for holding
steering rack
Upper wishbone
mounting provision
Lower wishbone
mounting provision

16. HUB NOMENCLATURE
Splines for
Axels
Press fitted
Wheel Nut
mountings
6 mountings for
Disk

17. ANALYSIS OF FRONT KNUCKLE MODEL

18. ANALYSIS OF REAR KNUCKLE MODEL

19. ANALYSIS OF REAR HUB MODEL

20. ANALYSIS OF FRONT HUB MODEL

21. RESULTS OF ANALYSIS
Model Max.
deformation
Max. stress
Front knuckle 15.94 mm 103.91 MPa
Rear knuckle 14.38 mm 93.074 MPa
Front hub 2.75 mm 34.263 MPa
Rear hub 1.29 mm 37.686 MPa

22. COST OF UPRIGHTS

24. MANUFACTURED KNUCKLES

27. MANUFACTURED HUBS

28. RESULTS
• Weight of front knuckle is 760 gm.
• Weight of rear knuckle is 900 gm.
• Weight of front hub is 1.5 Kg.
• Weight of rear hub is 1.5 Kg.

29. CONCLUSION
• Lighter weight of upright assembly and required stiffness is
achieved by optimum design calculations and less complex design.
Proper material selection of Al7075 is important factor in reducing the
weight of upright component without sacrificing in hardness and
strength of component. Analysis of upright component is done by using
ANSYS software and results obtained from analysis are within limits of
requirement. Means, Upright assembly proves its stiffness and
durability under stress consideration. Thus, Good performance to
weight ratio is achieved.

30. WORK DISTRIBUTION SHEET
(From July 15 to Feb.16)
Sr.
No
Work Work Assigned to Month
1
Review of literature from
international research paper and
journals
1. Mr. Pisat Sangram Kiran
2. Mr. Shinde Rohan Ramesh
3. Mr. Phule Aditya Sanjay
July-2015
2
Design selection of knuckle and
hub
1. Mr. Pisat Sangram Kiran
2. Mr. Shinde Rohan Ramesh
3. Mr. Phule Aditya Sanjay
August-2015
3 Material selection
1. Mr. Pisat Sangram Kiran
2. Mr. Shinde Rohan Ramesh
3. Mr. Phule Aditya Sanjay
August-2015
4
Design and development of 3D
Cad model
1. Mr. Pisat Sangram Kiran
2. Mr. Shinde Rohan Ramesh
3. Mr. Phule Aditya Sanjay
August-2015
5 Analysis of 3D Cad model 1. Mr. Shinde Rohan Ramesh
September-
2015

31. WORK DISTRIBUTION SHEET
(From July 15 to Feb.16)
Sr.
No
Work Work Assigned to Month
1
Visiting UNITY industries,
Karad.
1. Mr. Pisat Sangram Kiran
2. Mr. Shinde Rohan Ramesh
3. Mr. Phule Aditya Sanjay
December-
2015
2
Manufacturing of knuckle and
hub
1. Mr. Pisat Sangram Kiran
2. Mr. Shinde Rohan Ramesh
3. Mr. Phule Aditya Sanjay
February-
2016

32. FACILITIES AVAILABLE
Sr.
No
Nature of work Facility available
1 Review of literature
1. College Library- R.M.C.E.T.
Ambav
2. College Library – I.I.T. Mumbai
2 Design of knuckle and hub
CAD-CAM Department, RMCET,
Ambav
3
Analysis of knuckle and hub using
ANSYS
ELENO INSTITUTE, PUNE
4 Procurement MAHALAXMI steels, Thane
5 Fabrication UNITY Industries, Karad

33. REFERENCES
• [1] B. Bolles, Advanced Race Car Chassis Technology vol. HP1562: HP Trade,
2010.
• [2] P. G. Sturgess, Engineering Inspiration [Website], October 2013.
• [3] Josh Carrol, Lloyd Outten, Joseph Perry, Taylor Watkins, “ Formula SAE Team
Final Report” , Old Dominion University, April 2013.
• [4] G. B. Veeresh kumar, C. S. P. Rao, N. Selvaraj, M. S. Bhagyashekar, “ Studies
on AL6061-SiC and AL7075-Al2O3 Metal Matrix Composites ” , Journal of Mineral
and Material Characterization and Engineering
• [5] http://www.matweb.com/search/SpecificMaterial.asp?bassnum=MA7075T6

34. THANK YOU !!!