Failure Strength of Automotive Steering Knuckle Made of Metal Matrix Composite

This article presents the static performance of composite steering knuckle due to drive on an equivalent road, including different types of roughness and maneuvers. To achieve this purpose, the driving of a full-vehicle model was simulated using the multi-body dynamics (MBD) method, and the imposed loads on connection points of the steering knuckle to different components of the suspension system were extracted considering various maneuvers. Next, CATIA software was used to prepare a smooth model of the steering knuckle by employing coordinate measuring machine (CMM) data. Stress analysis was performed under the maximum value of the loading history in finite element (FE) software. Eventually, the safety factor was calculated based on some well-known criteria for static failure of the composite materials. Moreover, the optimum value of tungsten carbide as a reinforcing substance in aluminum composite was estimated to increase failure strength. The results show that an increase in tungsten carbide leads to an increase in the strength of the steering knuckle under purely axial loads (normal stress criterion) and also that an increase in this substance leads to a decrease in the strength of the part under shear loads (shear stress criterion). Therefore, based on the nature of the loads (i.e., multi-axial non-proportional random amplitude loading conditions) applied to the automotive steering knuckle due to actual conditions, this metal matrix composite (aluminum matrix and tungsten carbide as reinforcement) is not practical.