Numerical Study of Reinforced Aluminum Composites for Steering Knuckles in Last-Mile Electric Vehicles
The steering knuckle is a critical component of the suspension and steering drive systems of electric vehicles. The electrification of last-mile vehicles presents a challenge in terms of cost, driving range and compensation of battery weight. This work presents a numerical methodology to evaluate 60...
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| Format: | Article |
| Language: | English |
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MDPI AG
2024-03-01
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| Series: | World Electric Vehicle Journal |
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| Online Access: | https://www.mdpi.com/2032-6653/15/3/109 |
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| author | Carlos Santana Luis Reyes-Osorio Jesus Orona-Hinojos Lizbeth Huerta Alfredo Rios Patricia Zambrano-Robledo |
| author_facet | Carlos Santana Luis Reyes-Osorio Jesus Orona-Hinojos Lizbeth Huerta Alfredo Rios Patricia Zambrano-Robledo |
| author_sort | Carlos Santana |
| collection | DOAJ |
| description | The steering knuckle is a critical component of the suspension and steering drive systems of electric vehicles. The electrification of last-mile vehicles presents a challenge in terms of cost, driving range and compensation of battery weight. This work presents a numerical methodology to evaluate 60XX series aluminum metal matrix composites (AMMCs) with reinforcement ceramic particles for steering knuckle components in medium heavy-duty last-mile cargo vehicles. The use of AMMCs provides lightweight knuckles with sufficient strength, stiffness and safety conditions for electrical vehicle cargo configurations. The numerical study includes three aluminum alloys, two AMMC alloys and an Al 6061-T6 alloy as reference materials. The medium-duty heavy vehicle class < 12 t, such as electrical vehicle cargo configurations, is considered for the numerical study (class 1–4). The maximum von Mises stress for class 4 AMMC alloys exceeds 350 MPa, limited by fracture toughness. The weight reduction is about 65% when compared with commercial cast iron. Moreover, Al 6061-T6 alloys exhibit stress values surpassing 300 MPa, constraining their suitability for heavier vehicles. The study proposes assessing the feasibility of implementing AMMC alloys in critical components like steering knuckles and suggests solutions to enhance conventional vehicle suspension systems and overcome associated challenges. It aims to serve as a lightweight design guide, offering insights into stress variations with differing load conditions across various cargo vehicles. |
| first_indexed | 2024-04-24T17:44:45Z |
| format | Article |
| id | doaj.art-2813e70c52f34812a80536617d3b22f7 |
| institution | Directory Open Access Journal |
| issn | 2032-6653 |
| language | English |
| last_indexed | 2024-04-24T17:44:45Z |
| publishDate | 2024-03-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | World Electric Vehicle Journal |
| spelling | doaj.art-2813e70c52f34812a80536617d3b22f72024-03-27T14:08:39ZengMDPI AGWorld Electric Vehicle Journal2032-66532024-03-0115310910.3390/wevj15030109Numerical Study of Reinforced Aluminum Composites for Steering Knuckles in Last-Mile Electric VehiclesCarlos Santana0Luis Reyes-Osorio1Jesus Orona-Hinojos2Lizbeth Huerta3Alfredo Rios4Patricia Zambrano-Robledo5Facultad de Ingeniería Mecánica y Eléctrica, Universidad Autónoma de Nuevo León, San Nicolás de los Garza 66455, MexicoFacultad de Ingeniería Mecánica y Eléctrica, Universidad Autónoma de Nuevo León, San Nicolás de los Garza 66455, MexicoDataSc Consultancy Group, Saltillo-Coahuila 25084, MexicoDataSc Consultancy Group, Saltillo-Coahuila 25084, MexicoDataSc Consultancy Group, Saltillo-Coahuila 25084, MexicoFacultad de Ingeniería Mecánica y Eléctrica, Universidad Autónoma de Nuevo León, San Nicolás de los Garza 66455, MexicoThe steering knuckle is a critical component of the suspension and steering drive systems of electric vehicles. The electrification of last-mile vehicles presents a challenge in terms of cost, driving range and compensation of battery weight. This work presents a numerical methodology to evaluate 60XX series aluminum metal matrix composites (AMMCs) with reinforcement ceramic particles for steering knuckle components in medium heavy-duty last-mile cargo vehicles. The use of AMMCs provides lightweight knuckles with sufficient strength, stiffness and safety conditions for electrical vehicle cargo configurations. The numerical study includes three aluminum alloys, two AMMC alloys and an Al 6061-T6 alloy as reference materials. The medium-duty heavy vehicle class < 12 t, such as electrical vehicle cargo configurations, is considered for the numerical study (class 1–4). The maximum von Mises stress for class 4 AMMC alloys exceeds 350 MPa, limited by fracture toughness. The weight reduction is about 65% when compared with commercial cast iron. Moreover, Al 6061-T6 alloys exhibit stress values surpassing 300 MPa, constraining their suitability for heavier vehicles. The study proposes assessing the feasibility of implementing AMMC alloys in critical components like steering knuckles and suggests solutions to enhance conventional vehicle suspension systems and overcome associated challenges. It aims to serve as a lightweight design guide, offering insights into stress variations with differing load conditions across various cargo vehicles.https://www.mdpi.com/2032-6653/15/3/109steering knucklemetal matrix compositeslightweight designfinite element method |
| spellingShingle | Carlos Santana Luis Reyes-Osorio Jesus Orona-Hinojos Lizbeth Huerta Alfredo Rios Patricia Zambrano-Robledo Numerical Study of Reinforced Aluminum Composites for Steering Knuckles in Last-Mile Electric Vehicles World Electric Vehicle Journal steering knuckle metal matrix composites lightweight design finite element method |
| title | Numerical Study of Reinforced Aluminum Composites for Steering Knuckles in Last-Mile Electric Vehicles |
| title_full | Numerical Study of Reinforced Aluminum Composites for Steering Knuckles in Last-Mile Electric Vehicles |
| title_fullStr | Numerical Study of Reinforced Aluminum Composites for Steering Knuckles in Last-Mile Electric Vehicles |
| title_full_unstemmed | Numerical Study of Reinforced Aluminum Composites for Steering Knuckles in Last-Mile Electric Vehicles |
| title_short | Numerical Study of Reinforced Aluminum Composites for Steering Knuckles in Last-Mile Electric Vehicles |
| title_sort | numerical study of reinforced aluminum composites for steering knuckles in last mile electric vehicles |
| topic | steering knuckle metal matrix composites lightweight design finite element method |
| url | https://www.mdpi.com/2032-6653/15/3/109 |
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