IRJET- Material Optimization for Knuckle Joint by using FEA

International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 06 Issue: 10 | Oct 2019 www.irjet.net p-ISSN: 2395-0072
© 2019, IRJET | Impact Factor value: 7.34 | ISO 9001:2008 Certified Journal | Page 256
Material Optimization for Knuckle Joint by Using FEA
Somase Anil R1, Dhole Sumit M2, Bhavsar Urvesh P3, Shinde Tejas P4, Bhavsar Pritesh C5
1,2,3,4BE Student, Mechanical, SND COE & RC, Yeola, Maharashtra, India
5Professor, Mechanical, SND COE & RC, Yeola, Maharashtra, India
---------------------------------------------------------------------***----------------------------------------------------------------------
Abstract - Nowadays growth in competitionand innovationit
is needed to modify the existing products or replace old and
outdated products by newly innovated and advancedmaterial
products. The aim of the project is to study and calculate the
stresses in Knuckle joint using finite element method for
different material and out of that one material which satisfy
the objective of project is selected as a optimize material. The
knuckle joint is analyzed for structural steel, stainless steel,
aluminum alloy, Teflon, gray cast iron. It is found that
aluminum alloy is best optimizing material out of the selected
material. FEA results for tensile loading then validated with
tensile testing results at UTM. It has been observed that
stresses developed for knuckle joint made of magnesium are
least and the knuckle joint made of aluminum can sustain
maximum tensile load without failure.
Key Words: CATIA, ANSYS, UTM, FEA, Knuckle Joint,CAD
etc.
1. INTRODUCTION
nuckle joint is one of the most important type of mechanical
joint which is used in structures, to connect two intersecting
cylindrical rods. These rods axes will lieonthesameplane. It
permits angular movementbetweenthecylindrical rods.Itis
specially designed to withstandtensileloads. Knucklejointis
free to rotate about the axis of a knuckle pin.
It is basically a tensile joint. However, if the joint is guided, it
may support a compressible load. This joint can be readily
disconnected for adjustments or repairs. The common
examples of the knuckle joints are link of a roller chain,
tension link in a bridge structure, tie rod joint of roof truss,
tie rod joint of jib crank, etc. A typical knuckle joint consists
of three parts: an eye, a fork, and a knuckle pin. The end of
one rod is formed into an eye and the end of other rod is
formed into fork with an eye in each of the fork leg. The eye
is inserted into the fork and after aligning the holes in the
eye and fork, the knuckle pin is inserted through them. The
knuckle pin has a head at one end and at the other end it is
secured by a collar and a taper pin or split pin. The simple
definition of stress is that force divided by area.Iftheforceis
perpendicular to the area and pullingawayfromit,thestress
is tensile. If the force is perpendicular to area and pushing
towards it, the stress is compressive. Coaxial holes are
provided in the fork end, eye end and collar. The fork end
and the eye end are held together in position by means of a
knuckle pin. The knuckle pin is held in its position with the
help of a collar and a taper pin. The assembled view of a
knuckle joint is shown in the image below. Both the fork end
and the eye end are capable of rotating in their planes about
the axis of the knuckle pin.
A knuckle joint is used to connect two rods which are under
the action of tensile forces, when a small amount offlexibility
or angular moment is necessary. When the joint is guided, it
supports to a compressive load. This joint readily
disconnected for adjustments or repairs. The common
examples of the knuckle joints are found such as link of a
roller chain, tension link in a bridge structure, tie rod joint of
roof truss, tierod joint of jibcrank, etc. A typicalknucklejoint
consists of three parts. Its name is an eye, a fork, and a
knuckle pin. The end of one rod is formed into an eye and the
end of other rod is formed into fork with an eye in each of the
fork leg. The eye inserted into the fork and after aligning the
holes in the eye and fork, the knuckle pin is inserted through
them. The knuckle pin, it has a head at one end and at the
other end it is secured by a collar and a taper pin or split pin.
The knuckle joint has number of applications such as bicycle
chain, Tractors, Automobile wipers, cranes, robotic joints
structural members etc.
2. LITERATURE REVIEW
In this chapter the contribution made by different
researchers and authors in the field of manufacturing were
enlist in short. It consist the methods, mathematical
modeling, different input parameters well as their output
result.
Prof. Swati Datey et.al explained about Mahindra Tractor
joint. Tractor-trailer finds many use as a means of
transportation in rural like agriculturefieldandinurbanlike
goods transport as it is often cheaper. The effectivedesign of
any mechanical device will demand the predictive
knowledge of its behavior in workingcondition. Itbecomesa
necessity for the designer to know the forces and stresses
developed during its operation. In this project the stresses
on the knuckle joint and to improve the performance of
knuckle joint to a certain extent is going to be studied by
using CATIA V5 and FEM will be use analysis. Failure
analysis is the process of collecting and analyzing data to
determine the cause of a failure and how to prevent it from
recurring. Failure analysis and prevention are very
important to all of engineering disciplines. A component or
product failed in service or if failureoccursinmanufacturing
or during production processing. In any case, we should
determine the cause of failure to prevent future occurrence,
and/or to improve the performance of the device,
component or structure. It may be possible for fractureto be

a result of multiple failure mechanisms or root causes. A
failure analysis always provides the information to identify
the appropriate root cause of the failure. Not only Varying
load on pin and load on trailer can increase stress but
sudden impact due to unevenness of road can also cause the
failure of pin. After studying knuckle joint used in tractor-
trailer and analysis on knuckle pin following conclusion can
be drawn. AccordingtoourstudyTheoretical calculationand
FE analysis having around same results on 35 mm Diameter
at 50 KN. Secondly, we also find that material also plays a
very important role in stress reduction acting on joint
especially on pin. As we change material like grey cast iron
(ASTM grade 20 (EN-JL 1020), ASTM grade 35 (EN-JL1040),
ASTM grade 60 (EN-JL 1070)), Stainless steel and Titanium
alloy; deviations in Equivalent stress (von misses), shear
stress and total deformation occurs at same load and
diameter in which it has maximum stresses. As we increase
the force the von misses stress get increased on pin and can
lead to bending of pin but if we increase pin diameter , it will
sustain maximum stress at same force at which it has bend.
Bhokare Kiran et.al has predicted the fatigue of steering
knuckle arm of a sport utility vehicle while deploying
analytical techniques using CAE. Automobile components
and structures are subjected to cyclic loading and they are
consequently prone to fatiguedamage.Thesteeringknuckle,
being a part of the vehicles steering andsuspensionsystems,
undergoes time-varying loading during its service life. This
work shall be consisting ofanalyzingthesteeringknucklefor
the main operating conditions. The Finite Element
methodology would be adopted to solve the problem while
determining the fatigue life of the steering knuckle.
Prof. Nipun Kumar et.al explains in paper study the different
material. A knuckle joint made of various materials
magnesium alloy, aluminum alloy, stainless steel, structural
steel and gray cast iron is subjected to tensile load of 50 KN.
The stresses which is developed are found to be least for
knuckle joint made of magnesium alloy (170.6 MPa) while
the maximum stresses are found in knuckle joint made of
gray cast iron (176.77 MPa). Itis observed that knucklejoint
of aluminum alloy has highest factor of safety(1.641)among
considered materials and hence is best suited for 50 KN
loading condition.
Shankar Majhi et.al explained about Tractor and trailer. It is
a very useful component in agriculture field and
transportation the goods in rural and urban area. A knuckle
joint is used to connect the tractor and trailer. It consists of
eye forks and pin .The effective design of the component
which is attached to the trailer and tractor. In the knuckle
pin stresses are developed always during its operation.
When the vehicle is motion the forces is acting on the joint is
tensile and it’s opposite it is compressive. In the knuckle pin
stresses are developed always during its operation. Force
acting on the fork and pin will be calculated by the
theoretical study and analytical method. Subjected to high
stresses in pin going to be study by operating CATIA V5 and
finite element method to be used in analysis.
Sanjay Yadav et.al explained aboutthesteeringknucklejoint.
The Steering Knuckle component is the most important part
of vehicle which is connected to front wheel with the help of
suspension system, wheel hub and these are also connected
to steering system and brake to the chassis. The Steering
Knuckle component provides motion to desire directions
with the help of steering system. It undergoes various types
of varying load under different conditions. In Automobile
industry low fuel consumption and light weight are the two
main demands for the vehicle because the lighter steering
knuckle resulting greater power and less vibration because
of inertia is less. In this Paper we have done static analysisof
steering knuckle component.
3. PROBLEM IDENTIFICATION
To suggest appropriate material for Knuckle joint with cost
effectiveness and to increasing the life of knuckle joint used
for Mahindra tractor.
3.1 Need of Study
 To decide the best suitable material for Knuckle
joint from available materials for same load
carrying capacity.
 To modify the geometry if necessary
 To reduce cost of knuckle joint.
 To analyze the stresses using ANSYS software
calculations.
 To improve the life of knuckle joint.
3.2 Aim
To find out Alternative Material to minimize costandweight
of knuckle joint and also increase the life of joint and for that
the study of different type of material is carried out.
4. MATERIAL SELECTION FOR ANALYSIS
The basic question is how can we go about selecting a
material for a given part? This may seem like a very
complicated process until we realize than we are often
restrained by choices we have already made. Materials are
subjected to forces (loads) when they are used. Mechanical
engineers calculate forces and material scientists how
materials deform (elongate, compress,andtwist) orbreak as
a function of applied load, time, temperature, and other
conditions. A materials scientist learns about these
mechanical properties by testing materials.Aresultfromthe
tests depends on the size and shape of material which is to
be tested (specimen), how it is held, and the way of
performing the test.Thatiswhyweusecommonprocedures.

The engineering tension test is used to provide basic design
information on the strength of materials and as an
acceptance test for the specification of materials. In the
tension test a specimen is always subjected to a continually
increasing uniaxial tensile force while simultaneous
observations are made of the elongation of the specimen.
The parameter, which is used to describe, the stress- strain
curve of a metal, are the tensile strength, yield strength or
yield point, percent elongation, and reduction of area.
The stress-strain curve characterizes the behavior of the
material which is to be tested. It is mostly plotted using
engineering stress and strain measures, because the
reference length and cross-sectional area are easily
measured. Stress-strain curves generated from tensile test
results helps for engineers gain insight into the constitutive
relationship between stress and strain for a particular
material. The constitutive relationship can be thought of as
providing an answer of the following question after given a
strain history for a specimen, what is the state of stress? As
we see, even for the simplest of materials, this relationship
may be very complicated. In addition toprovide quantitative
information that is useful for the constitutive relationship,
the stress-strain curve can be used to qualitatively describe
and classify the material. Typical regions observed in a
stress-strain curve are
[1] Elastic region
[2] Yielding
[3] Strain Hardening
[4] Necking and Failure
A stress-strain curve with each region will be identified is
shown below. The curve has sketched using the assumption
that the strain in the specimen is monotonically increasing -
no unloading occurs. It would also be emphasized that a lot
of variation from what's shown is possible with real
materials, and each of the above regions will not be so
clearly delineated. It will be emphasized that the extent of
each region in stress-strain space is material dependent,and
that not all materials exhibit all of the above regions.
Fig -1: Stress vs. strain diagram
4.1 Yield Strength
The yield point defined as the stress at which a material will
try to begin to plastically deform. Prior to the yield point the
material will be deformed elastically and will return to its
original shape when the applied stress is removed. Once the
yield point is passed some amount ofthedeformationwill be
permanent and non-reversible. Knowledgeoftheyieldpoint
is very important when designing a component since it
generally represents an upper limit to the load that can be
applied. It was very important for the control of many
materials production techniques such as forging, rolling, or
pressing. In structural engineering, yield is the permanent
plastic deformation of a structural member when it goes
under stress. This is a very soft failure mode which does not
normally cause catastrophic failure unless it accelerates
buckling. It is difficult to precisely define yield due to the
wide variety of stress-strain behaviors’ exhibited by real
materials. In addition there is other possible ways to define
the yield point in a given material. Yield occurs when
dislocations first begin to move.
4.2 Elastic Limit
The lowest stress at which permanent deformation can be
measured this requires a complex iterative load-unload
procedure and is critically dependent on the accuracy of the
equipment and the skill of the operator.
4.3 Proportional Limit
There is a point at which the stress-strain curve may be
nonlinear in most metallic materials the elastic limit and
proportional limit are essentially the same.
4.4 Yield Point
When the stress is too large, the strain deviates from being
proportional to the stress. Yield point is the point at which
this happens is because there the material yields, deforming
permanently.
4.5 Yield stress
Hooke's law is not valid beyond the yield point. The stress at
yield point is always called yield stress, and is an important
measure of the mechanical properties of materials. In
practice, the yield stress is chosen as that causing a
permanent strain of 0.002, which called as proof stress.
4.6 Steel
Steel is another option to be used as a material for Knuckle
joint. Steel is also better choice because, it possess excellent
mechanical characteristics which suits best with the
operational requirements of knuckle joint. It has the highest
modulus of elasticity. It is tough, strong, easily available,and
cheap and it has very less coefficient of thermal expansion
which makes it best suited for high temperature operation.

Steel has a large number of variants which possess large
range of properties. Hence, selection of most appropriate
type of steel is very important. Medium-carbon steel alloys
are composed of predominantly the element iron, and
contain a small percentage of carbon (0.25% to 0.45%,
described as 25 to 45 points of carbon), along with
combinations of several alloying elements, the mix of which
has been carefully designed in order to produce specific
qualities in the target alloy, including hardenability,Nitride-
ability, surface and core hardness, UTS, yield strength,
endurance limit (fatigue strength), ductility, impact
resistance, corrosion resistance, and temper embrittlement
resistance. The alloying elements usually used in these
carbon steels are manganese, chromium, molybdenum,
nickel, silicon, cobalt, vanadium, and sometimes aluminum
and titanium. Each of those elements adds specific
properties in a given material. The carbon content is the
main factor to decide of the ultimate strength and hardness
to which such an alloy can be heat treated.
4.7 Aluminum
Aluminum is an excellent machinability metal. It is light
weight and can take complex shapes easily. Moreover, it can
absorb vibration very efficiently. The history of the industry
such as light metal as that of many other industries in this
century is one of notable and ever accelerating expansion
and development. There are few people today who are not
familiar with at least some modern application of aluminum
and its alloys. The part it plays in our everyday life is such
that it is difficult to realize that a century ago the metal was
still a comparative misty. The excellent corrosion resistance
of pure aluminum was large due to its affinity for oxygen;
this results in the production of a very thin but tenacious
oxide film which covers the surface as soon as a freshly-cut
piece of the metal is exposing to the atmosphere. This oxide
coating has great significanceintheproductionofpractically
every type of surface finish for the metal. It was, of course,
the basis of what was probably the most corrosion-resistant
finish of all, namely, that group of finisheswhichinvolvesthe
technique of anodic oxidation in its varied forms. Here, the
natural film is, in effect, greatly thick and strength due to
electrochemical means. Ontheother hand,thetenacityof the
natural oxide film is a serious adverse factor in the
production of other finishes, such as those based on
electrodepositing, and also, buttoa lesserextent,theorganic
finishes, as it must be removed or transformed before the
alternative coating can be successfully applied. Special
techniques have had to be evolved to affect this.
5. MATERIAL SELECTION BY FINITE ELEMENTANALYSIS
5.1 Tool Used
Here Ansys 16.0 is used for analyzing natural frequencies
and static deflection. CAD modeling is done inCatia software
and .stp file were imported in ANSYs for analysis. Ansys
Mechanical software is a very comprehensive FE analysis
(finite element) tool for structural analysis, including linear,
nonlinear and dynamic studies. The engineering simulation
product always provides a complete set of elements
behavior, material models and equation solvers for a wide
range of mechanical design problems. In addition, ANSYS
Mechanical always offers great thermal analysis and
coupled-physicscapabilities involvingacoustic,piezoelectric,
thermal–structural andthermo-electricanalysis.Witha solid
foundation of element and material technology, ANSYS
structural analysis software offer different type of advanced
modeling methods for different kinds of applications. In
addition, ANSYS finite element analysis (FEA) tools offers
great advanced capabilities that enable simulation of a
variety of physics phenomena, such as thermal–stress,
electromechanical, structural–acoustics, mass diffusion and
simple thermal–fluid analysis.
5.2 Static Analysis
A static structural analysis always determines the
displacements, stresses, strains, and forces in structures or
components caused by loads that do not induce significant
inertia and damping effects. Steady loading and response
conditions are to be assumed; that is, the loads and the
structure's response are assumed to vary slowly with
respect to time. A static structural load can be performed
using the ANSYS solver.
5.3 Geometry Details
CAD Modeling of any project isverytimeconsumingprocess.
One can’t shoot directly from the form sketches to Finite
Element Model. CAD (Geometry) Modeling is the base of any
project. Finite Element software will be considered for
shapes, whatever is made in CAD model. CAD modeling of
the knuckle joint is performed by using Catia.
Fig -2: Model of knuckle joint

5.4 Contact
5.4.1 Bonded Contact
Fig -3: Bonded Contact
5.4.2 Frictional Contact
Fig -4: Frictional Contact
5.5 Meshing
Meshing consist division of the entire of model into small
pieces called elements. This is done by meshing. It is
convenient to select the free mesh because the sharpcurves,
so that shape of the object will not alter. To mesh the plate
the element type must be decided first. SOLID187 is used
here for meshing plates.
Fig -5: Meshing of model
5.6 Loads and Boundary Conditions
Eye end is fixed in all directions and force is applied on fork
end. Below Figure shows loads and bc's knuckle joint. Same
bc's are applied for cases of material models.
5.6.1 Fixed Support
Fig -6: Fixed Support
5.6.2 Force =5KN
Fig -7: Force

5.6.3 Force =50KN
Fig -8: Force
6. RESULT
6.1 Von Mises Stress Plot
In figure 9 shows Von mises stress plot of Aluminum alloy.
Here red color indicates maximum stress, while blue color
indicates minimum stress. From the above figure it is clear
that maximum stress in single eye is at inner face where we
select bonded contact and hence we are notselectthatstress
for analysis.
Fig -9: Von Mises Stress Aluminum
6.2 Total Deformation
Table -1: Stresses in knuckle joint
Sr.
No.
Material Von Mises Stress
(MPa)
Material
Yield
StrengthEye Fork Pin
1 Structural
Steel
80 33 63 250
2 AL Alloy 79 32 62 280
3 Teflon 79 33 58 105
Table -2: Total deformation of selected material
Sr. No. Material Total Deformation(mm)
1 Structural Steel 0.053
2 AL alloy 0.144
3 Teflon 20.537
7. CONCLUSIONS
Aluminum alloy and Teflon shows very less weight as
compare to other material but Teflon have a less strength.
Hence FOS is less as compare to aluminum alloy so that we
choose aluminum alloy as a best optimize material by using
FEA. The total deformation is aluminum alloy is less as
compare to Teflon material. The von misses stresses is less
aluminum alloy as compare to Teflon and material strength
is high.
Knuckle joint was analysis for five different materials.
Static deformation of AL allot knuckle joint was validated
with experimental. Good agreement is observed for
experimental measure static deformation in UTM and FEA
results. The results are validated and hence wecanconclude
that the ANSYS results are reliable and can be applied for
complicated analysis.

 Steel FOS are higher than min requirement of 3,
however the material cost and mass of steel is
higher compared all other material.
 Steel and CI having similar FOS and mass of knuckle
also seems comparative and hence both materials
were not recommended.
 AL material is sustaining tensile loading of 50KN
with min FOS of 3.5
 Deformation of steel and AL material are very less
co pared to Teflon and CI.
 Material cost of Teflon is less compared all other
material along with FOS and hence Teflon will not
be good material even having less mass.
 AL is having highest FOS and less mass comparedto
steel and CI and hence based FEA study we
recommended to manufacture knuckle joint in
future with AL material.
8. REFERENCES
1. B.D. Shiwalkar, (2011), Design of Machine Element,
S Chand Publishers, Delhi.
2. Prof. Swati Datey, Amit A. Rangari, Adarsh A.
Dongre, Kunal A. Paraskar, SanketV.Lidbe,Analysis
of Knuckle Joint used in Mahindra 575 DL, IJARIIE-
ISSN(O)-2395-4396, Vol-3 Issue-2 2017.
3. “DIAMETER AND SPIRAL THICKNESS
OPTIMIZATION OF KNUCKLE JOINTUSINGNEURAL
NETWORK” Pankaj Dulani, Rungta College of
Engineering & Technology, Bhilai, Chhattisgarh,
India S. A. K. Jilani Professor, Rungta College of
Engineering & Technology, Bhilai, Chhattisgarh,
India Vol-3 Issue-2 2017 IJARIIE-ISSN(O)-2395-
4396
4. “EVALUATION OF USING HIGH STRENGTH LOW
ALLOY STEEL FOR DESIGN OF KNUCKLE JOINT”
Engr. Dr. Fathi Abusa, Associate Professor,
Department of Mechanical Engineering,AL-Zaytona
University, Libya Engr. Dr. Fuzi Abusa A lecturer,
Department of Mechanical Engineering,AL-Murgab
University, Libya
5. “FE ANALYSIS OF KNUCKLE JOINT PIN USEDIN
TRACTOR TRAILER” Dinesh Shinde and Kanak
Kalita Department of Mechanical Engineering,
MPSTME, SVKM’s NMIMS, Shirpur Campus, Dhule,
Maharashtra, India.
6. “STUDY AND ANALYSIS OF PIN OF KNUCKLEJOINT
IN TRAIN” Ravindra S. Dharpure, M.Tech., PCE,Prof
D. M. Mate, PCE, Nagpur.
7. “MODELING AND ANALYSIS OF KNUCKLE JOINT”
Shaik .John Bhasha M.Tech Student, Department of
Mechanical Engineering,Visakha Technical Campus,
Narava. Hari Sankar Vanka Asst. Professor,
Department of Mechanical Engineering, Visakha
Technical Campus, Narava.
8. “STUDY &ANALYSISOFKNUCKLEJOINTWITHTHE
REPLACEMENT OF MATERIAL BY USING TEFLON”
Nishant Vibhav Saxena Assistant Professor,
Department of Mechanical Engineering, MITS,
Bhopal, MP Dr. Rohit Rajvaidya Professor,
Department of Mechanical Engineering, BUIT,
Bhopal, MP.
9. Kiran S.Bhokare, G.M.Kakandikar, Swapnil S.
Kulkarni, Predicting the fatigue of steering knuckle
arm of a sport utility vehicle while deploying
analytical techniques using cae, International
Journal of Scientific Research and Management
Studies(IJSRMS) , Volume 1 Issue 11, pg: 372-38.
10. Nipun Kumar, Dr. GianBhushan, Dr. Pankaj
Chandna, Analysis of Knuckle Joint of Various
Materials using CAE Tools, International Journal of
Engineering Technology, Management and Applied
Sciences, January 2017, Volume 5, Issue 1, ISSN
2349-4476.
9. BIOGRAPHIES
Mr. Somase Anil Ramesh
B E Student
S.N.D C.O.E. & R.C Yeola
Mr. Dhole Sumit Madhukar
B E Student
Mr. Bhavsar Urvesh Pramod
B E Student
Mr. Shinde Tejas Pravin
B E Student

Prof. Bhavsar Pritesh C
Asst. Professor

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IRJET- Material Optimization for Knuckle Joint by using FEA