Investigation of Knuckle Joint and Its Importance
Investigation of Knuckle Joint and Its Importance
Investigation of Knuckle Joint and Its Importance
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Mani Shrivardhan
Mechanical Engineering
Sri Venkateswara College of Engineering SVCE
Chennai, India
e-mail: shrivardhanmsv@gmail.com
Abstract—There has been deluged and overflowing disconnected. Fatigue was found out in the 19th century [1]
composition published in knuckle joints and its importance in and was also guesstimated using durability tests [2] The
automobile industries. Achieving manufacture excellence main parameters where failure occurs during the
through better quality and productivity is the objective lens of manufacturing of Knucle joints are: calliper wall thickness
many industries in present. Every governance is trying hard in (DESIGN) [3], damper thickness, environmental factors,
the process of customer retention (Voice of The Customer joint thickness and many minor faliures as well. In the recent
VOC and Critical To Quality CTQ) by controlling costs and studies the factor of safety of joints is said to be from 3-4 [4]
obtaining high productivity. A voluminous and significant
and the rejection rate in every manufacturing unit is
measure of research article were referred in which all the
papers concentrated one and only on the final product with
13.8%/month [5] which results to Improper loading,
some investigation on dimensional accuracy, which includes - Operating Different Batch, Over Drafting Projection in
Cycle time reduction, degree of doubt and the proper Casting, Over Projection & Bend in Tie Rod Area, Clamping
placement of the knuckle part. CMM (Cast Component Pressure Low, Design of fixture & Wrong Setting [6].
Machining) is used for uncovering the dimension during Knuckle joints can be made of many materials like stainless
improper and proper casting. A case study of an automotive steel, structural steel, Gray cast iron magnesium and gray
manufacturing company has been clearly stated by explaining cast iron. All these materials were analyzed for stress and
the common failures occurring in the manufacturing of deformation under different loading conditions. The analyses
knuckle joints. were done by CATIA and ANSYS and the resultant output
was that the knuckle joint made of Al (aluminum) [7] could
Keywords-knuckle joint; calliper wall thickness; casting; sustain maximum tensile load without failure. [8] Many
CMM; damper problems have raised in the past like increasing cost and
I. INTRODUCTION difficulty in operation due to many check portions and link
ups, secondly the complexion in the structure resulting to
A mojor complication in the automobile industries is the malfunction, which has clearly changed a revolution in
existence of instablity in the substanial properties and creating a ladder with conventional method of adjustments in
manufacturing processes. knuckle joints are basically two or the knuckle joints.
more rods superintend to tensile and compressive forces are
fastened together which allows a small angular moment of II. LITERATURE REVIEW
one to another. They are indeed rod-couplings whih are used
A. Design and Stress Analysis
to connect the members in trusses and other structures and
cannot be used as a power transmitting component. Knuckle Stress and static analysis often results to increasing brake
goes by different names steering knuckle, wheel carrier and efficiency and reduction of stoppage distance, which in turn
upright. It is called the nexus of a vehicles front axle. They increases fuel efficiency, and reduces the emission Stress
are designed mainly in two types : one with the Hub and the analysis could be done in any part of the knuckle joint by
other comes with the spindle, both have equal advantages CATIA, ANSYS, mainly concentrating on the stress
and disadvantages factors. Knuckle has become one of the (Internal and external), the imposed displacement, inertial
most important components in every mechanism starting force and temperatures [9] the Cycle time reductions were
from automobiles to human anatomy, in other words further refurbished with [10] value stream mapping, kaizen
biomechanics. Knuckle can be easily connected and (continuous improvement), [11] six sigma implementation,
63
for a knuckle joint device, which had to be durable and time quality assurance factors and the parameters that are
dependent. The basic objective of the invention is that to associated with the quality improvement which has the
provide a connecting rod to simplify the production of a greatest effect [47]
toggle-joint device and to ensure that it works properly [28].
Pivoting motion of the knuckle joint has been discussed in
this patent, which is controlled by an actuator (which is
hydraulic). The pivoting internal arrangement is so flexible
(elastically) [29] that the efficiency is optimum when
compared to the other inventions. Due to the elastically pivot
structure the research has proved that there could be any
number of adjustments in the moving direction.
E. Limitations on the Literature Review
1. The researchers who have performed design analysis
and simulation have not referred to the patents that
are present, which lags consideration of type of
material, load factors and failure at different
conditions.
2. Most of the research has concentrated only in failure
analysis of automobile, mechanical equipment’s and
not on other applications like biomechanics, toggle
devices and other applications.
Figure 2. Defects wise Pareto analysis
Now this paper is basically on a literature study on
knuckle joints, on how mainly steering knuckle was used,
their history, their parametrical characteristics, causes of
failure, testing under different scenarios and final their
structural functions. A case study has been explained by
taking a company’s case study in which the damper
thickness and caliper height was mainly intensified with
step-by-step manifestos (diagrams, cad drawings, Pareto
charts, before and after instances, solutions and design
modifications).
Figure 3. (a) Knuckle joint view (b) Lesser caliper wall thickness
64
Figure 4. Month wise rejection rate (PPM)
The common possible causes found out during the pareto Figure 7. Operation sequence in order
analysis while manufacturing the knuckle joint was as TABLE II. PROCESS STAGES INVOLVED DURING MANUFACTURING OF
follows- Improper loading, Operating different batches in the KNUCKLE JOINT
shift, over drafting projection in Casting, over projection and
bend in Tie rod area, Low clamping pressure, Design of S.NO PROCESS NUMBER PROCESS NAME
fixture and wrong setting. 1. #05 INCOMING INSPECTION
2. #10 TURNING
6. #70 DESPATCH
65
Figure 9. Operation, during Butting in Damper Area Over Drafting
Projection found in Casting.
Figure 11(b). Operation #20 Drilling, thickness NG found.
Figure 12. (a) Existing Damper Area (b) Modified Damper Area
66
Figure 13. Design analysis using ANSYS
67
Design analysis is performed with the Cast Iron Grade 20, After the change of the damper butting area the NG
keeping the parameters constant the different kinds of (ERROR) parts have been rectified and the rejections have
simulation is shown and by comparing Figure 10 and 14 with also been reduced.
respect to the calliper wall thickness, we can come to a
conclusion that deformation occurs due to over drafting.
Thus, with the above proof we can surely suggest that there
has to be a minor change in the structure of the knuckle joint.
Compare Figure. 10 and 14 for the calliper wall thickness
structural arrangement
Figure 18. (a) Analysis of Non Conformities Before (b) Analysis of non
after conformities
Figure 15. (a) Existing Design in damping area (b) Modified Design in
damping area
Figure 19. Pareto Analysis after development in the calliper wall thickness
Figure 16. (a). Over Drafting Projection (b). Damper butting area Modified Comparing the Figure 2 and Figure 17 and reducing the
In damper butting area over draft in casting and re positioning the knuckle part the
final status could be concluded.
Figure 17. (a). knuckle joint L design BEFORE (b) knuckle joint L design Figure 20. Graph showing the reduction in PPM count
AFTER
68
[10] Venkataraman, K., B. Vijaya Ramnath, V. Muthu Kumar, and C.
Elanchezhian. "Application of value stream mapping for reduction of
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[11] Singh, Amit Kumar, and Dinesh Khanduja. "Defining Quality
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[12] Han, Kwan Hee, Geon Lee, and Sang Hyun Choi. "Manufacturing
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Figure 21. Change in COPQ (COST OF POOR QUALITY) and its % for Knuckle Joint with the Replacement of Material by Using
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thickness rejections have been reduced to 5 parts from 32 [17] Pantazopoulos, G., A. Sampani, and E. Tsagaridis. "Torsional failure
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[18] Sonsino, C. M. "Fatigue testing under variable amplitude
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