Download - ME 273 - FEA Project
STRUCTURAL ANALYSIS AND
OPTIMIZATION ON COM–
PONENTS OF KNUCKLE JOIN
Anu Nair Krishnaswamy Mahadevan
Robinpreet Dhillon
Faculty Mentor: Eduardo Chan, PhD
Project Sponsors: ANSYS,Inc
Abstract
Knuckle joint is a type of mechanical joint used in structures, to connect two intersecting cylindrical
rods, whose axis lie on the same plane. It permits some angular movement between the cylindrical
rods. It is specially designed to withstand tensile loads. In this project, we have designed two major
components of knuckle joint in ANSYS WORKBENCH and statically analyzed by applying tensile
loads in the direction of rod end. In this project we have also done shape optimization in ANSYS
WORKBENCH with the objective to reduce weight.
Knuckle Joint Assembly
Introduction
In this project we have structurally analyzed and
optimized two major parts of knuckle joint: Fork end
and Eye end. The main objective is to reduce the mass
and total deformation of both components for various
parameters to get better design criteria.
A typical knuckle joint has the following parts:
1. Fork end
2. Eye end
3. Knuckle pin
4. Collar
5. Taper pin
Exploded view of Knuckle joi
Pre-optimization
Following Material was selected for this project:
Meshing of Eye end and Fork end was done by using Face Sizing and Relevance Factor on parts where we
expected higher deformation.
Eye end Fork end
Relevance 100 100
Relevance Center Fine Fine
Face Sizing 0.5 mm 0.5 mm
Average Element quality 0.8 0.77
Average Aspect Ration 1.9 2
Average Skewness 0.29 0.33
Generated mesh
Eye end
Fork end
Boundary conditions
Fixed Support Pin end (where pin is being
inserted)
Pin end (where pin is being
inserted)
Load 30,000 N 30,000 N
Analytical Calculations
D = √4𝑃
𝜋[𝜎]
30 𝑚𝑚 = √4 ×30000
𝜋×[𝜎]
[𝜎 ] = 43 N/𝑚𝑚2
[𝜎] = 𝑆𝑦𝑡
𝐹𝑂𝑆
43N/𝑚𝑚2 = 400
𝐹𝑂𝑆
FOS= 9.3
D= Diameter of the rod
[𝜎] = Permissible stress
P = Applied force
𝑆𝑦𝑡= yield stress of material
FOS =factor of safety
Pre-Optimization Results
Total deformation Total deformation
Von mises stress Von mises stress
Proposed Shape Optimization
Eye End Fork End
The above images shows the shape optimization results for the eye end and fork end
Post-optimization
Fork End Response Surfaces
Eye End Response Surfaces
Optimized Total Deformation Optimized Total Deformation
Optimized Von Mises Stresses Optimized Von Mises Stresses
Conclusion
Fork end results after Optimization Eye end results after Optimization
The above tables summarize the final optimization results of Fork end and Eye end.
Team was successfully able to reduce mass and deformation of fork end and eye end in ANSYS Workbench
software. We have found out that mass reduces by 1.2% for fork end and 1.05% for eye end. The change in mass
and total deformation is achieved by altering edge fillet radius and square radius for eye end and fork end.
Before After
Edges (All4) 3 mm 6.3mm
Square Radius 2 mm 5 mm
Filleted Radius 2 mm 5 mm
Total Deformation 0.018648 mm 0.01857 mm
Mass 1.394 kg 1.325 kg
Before After
R2 59.5 mm 56 mm
Edge (All 4) 3 mm 7 mm
Total Deformation 0.024587mm 0.024254 mm
Mass 2.42 kg 2.38 kg