The steering knuckle component is a valuable auto part that connects the multi-axial loads and fatigue stresses of the wheel hub, suspension and steering systems. Poor road conditions in Nigeria such as potholes and non-even surfaces among other factors coupled with overloading and poor maintenance of the roads contribute to the faster wear of the components, hence necessitating special design to increase durability and reliability. This study is dedicated to the design and analysis of a steering knuckle that is optimized for the Nigerian roads, which is in line with SDG 9 industry and infrastructure innovation. A 3D model was created in SolidWorks and was based on a Toyota Corolla of 2006, with the features of the suspension mount, tie-rod arm, and brake caliper mount. In ANSYS Workbench, a Finite Element Analysis (FEA) was utilized to check the performance under dynamic loads that comprise of the axial, inertia, and bending forces with a weight of 1250 kg and a dynamic factor of 2.0 to test it under harsh conditions. They were compared with two materials, which were ductile cast iron and aluminium alloy 6061. The findings revealed that ductile cast iron had reduced deformation (0.012 mm), stress (185 MPa), and better factor of safety (FOS) of 1.729, which would be better when subjected to rugged conditions. The streamlined design can be used to guide the indigenous engineers in their efforts to encourage lightweight but strong parts to enhance the safety and lifespan of the cars on the Nigerian roads.

Keywords

Steering Knuckle, Nigerian roads, Finite Element Analysis (FEA), Ductile Cast Iron, Von Mises Stress.