765 – Design and Analysis of Steering Knuckles

Project Assignment: Design and Analysis of Steering Knuckles

You are required to complete a comprehensive engineering project titled Design and Analysis of Steering Knuckles for the Automotive Manufacturing module. The work must be carried out professionally, following academic standards, and must demonstrate a strong understanding of materials, manufacturing processes, and process management.

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### Project Deliverables

1. A 20-page technical report

2. A 15-minute presentation (PowerPoint)

3. Preparation for a viva (oral examination)

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## 1. Materials and Process (Part 1)

You are required to:

– Identify and discuss the functional and mechanical requirements of a steering knuckle.

– Select appropriate materials using the CES (Cambridge Engineering Selector) tool.

– Evaluate at least three different engineering materials, including one advanced material.

– Compare the materials based on:

– Strength

– Weight

– Cost

– Durability

– Machinability

– Use charts and tables to support your analysis.

– Clearly justify the final material selection.

– Determine whether the design is performance-driven or cost-driven.

– Propose suitable post-processing techniques, such as heat treatment or surface treatment.

### Machine-Ready Knuckle

– Propose a suitable pre-form manufacturing method (e.g., forging, casting).

– Ensure the design minimizes machining requirements.

– Include schematic diagrams and explain machining allowances.

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## 2. Process Control and Management (Part 2)

### Toyota Production System

– Provide a clear summary of the Toyota Production System (TPS).

– Explain how lean manufacturing principles can be applied to the company.

### Process Capability

– Identify appropriate methods to improve process capability.

– Explain implementation strategies with examples.

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## 3. Manufacturing Process (Part 3)

### Using SolidWorks

– Perform manufacturing cost analysis using SolidWorks.

– Include screenshots showing:

– Cost parameters

– Assumptions (e.g., labor cost)

– Justify all assumptions.

– Compare results with real-world cost estimates from reliable sources.

### Using CES Software

– Generate and analyze the following graphs:

– Tolerance vs Shape

– Surface Roughness vs Process

– Economic Batch Size

– Include screenshots for all stages.

– Select the most suitable manufacturing process and justify your decision.

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### Tooling and Production Setup

– Propose appropriate CNC milling tools.

– Discuss work-holding methods.

– Explain the role of:

– CAM systems

– Post-processors

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### Enabling Technologies

– Evaluate modern technologies for future manufacturing (Industry 4.0 / 2030).

– Suggest improvements for smart manufacturing environments.

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## Report Structure

Your final report must include:

1. Executive Summary

2. Table of Contents

3. Part 1: Materials and Processes

4. Part 2: Process Control and Management

5. Part 3: Manufacturing Processes

6. References

7. Appendices

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## Additional Requirements

– Include calculations using Excel or MATLAB where necessary.

– Clearly present all formulas used.

– Use proper academic referencing.

– Ensure the report is well-structured, clear, and professional.

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## Presentation Requirements

– Prepare a 15-minute PowerPoint presentation summarizing:

– Problem statement

– Material selection

– Manufacturing process

– Key findings

– Be ready to answer questions related to:

– Materials

– Manufacturing

– Process management

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## Important Notes

– The work must be original and free from plagiarism.

– Multiple solutions are acceptable, but all decisions must be well-justified.

– Emphasis should be on engineering judgment, analysis, and clarity.

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End of Assignment

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