Resincap Journal of Science and Engineering
Volume 2, Issue 5 May 2018
Optimization of knuckle joint by using finite element analysis and
its experimental validation
Mr.Nitin Paraji Jondhale
P G Student
S.N.D.C.O.E.&R.C Yeola
nitinjondhale22@gmail.com
ABSTRACT
The aim of this paper is to study and calculate the stresses in
Knuckle joint using analytical method and its validation
through experiment. A knuckle joint is used to connect two
rods under tensile load. These joints are used for different
types of connections e.g. tie rods, tension links in bridge
structure. In this, one of the rods has an eye at the rod end and
the other one is forked with eyes at both the legs. In this
study, modeling and analysis of a knuckle joint is performed
by using Finite Element Method. The commercial finite
element package ANSYS version 16 will be used for the
solution of the problem. The knuckle joint takes tensile loads
often, thus there is a need for quality design tools. The
modeling of the knuckle joint is done using 3D software. Here
CATIA or Cre-O will be used for modeling. The simulation
part will be carried out using the Analysis software, ANSYS.
With the Boundary constrains and the tensile load applied, the
knuckle joint is analyzed and the values are tabulated. FEA
results for tensile loading then validated with tensile testing
results at UTM.
Keywords
FEM, UTM, Tensile Testing, Experimental Validation.
1. INTRODUCTION
Knuckle joint is a type of mechanical joint used in structures,
to connect two intersecting cylindrical rods, whose axes lie on
the same plane. It permits some angular movement between
the cylindrical rods (in their plane). It is specially designed to
withstand tensile loads. Knuckle joint is named so because it
is free to rotate about the axis of a knuckle pin.
Figure 1.Typical Knuckle Joint
It is basically a tensile joint. However, if the joint is guided, it
may support a compressible load. This joint can be readily
ISSN: 2456-9976
Prof.Karwande A.H
Asst.Professor
S.N.D.C.O.E.&R.C Yeola
karwandeah@gmail.com
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. If the force is
perpendicular to the area and pulling away from it, the stress
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.
2. PROBLEM STATEMENT
To suggest appropriate material for Knuckle joint with cost
effectiveness and to increasing the life of knuckle joint used
for Mahindra tractor.
2.1 Need of Study
 To decide the best suitable material for Knuckle
joint from available materials for same load
carrying capacity.
 To reduce cost of knuckle joint.
 To improve the life of knuckle joint.
 To analyze the stresses using Ansys software
calculations.
 To modify the geometry if necessary
2.2 Aim
To find out Alternative Material to minimize cost and
weight 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 SELECTIONS BY FINITE
ELEMENT ANALYSIS
4.1 Tool Used
375
 Resincap Journal of Science and Engineering
Volume 2, Issue 5 May 2018
ISSN: 2456-9976

Here Ansys 16.0 is used for analyzing natural frequencies and 4.4. Geometry Details
static deflection. CAD modeling is done in Catia software and
.stp file were imported in ANSYs for analysis. Ansys CAD Modeling of any project is one of the most time
Mechanical software is a comprehensive FE analysis (finite consuming process. One cannot shoot directly from the form
element) tool for structural analysis, including linear, sketches to Finite Element Model. CAD (Geometry)
nonlinear and dynamic studies. The engineering simulation Modeling is the base of any project. Finite Element software
product provides a complete set of elements behavior, will consider shapes, whatever is made in CAD model. CAD
material models and equation solvers for a wide range of modeling of the knuckle joint is performed by using Catia.
mechanical design problems. In addition, ANSYS Mechanical
offers thermal analysis and coupled-physics capabilities
involving acoustic, piezoelectric, thermal structural and
thermo-electric analysis. With a solid foundation of element
and material technology, ANSYS structural analysis software
offers various advanced modeling methods for different kinds
of applications. In addition, ANSYS finite element analysis
(FEA) tools offer 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.
Fig.2.Knuckle Joint.
4.2 Static Analysis
Knuckle joint is another promising joint to join rods and carry
A static structural analysis determines the displacements, axial force. It is named so because of its freedom to move or
stresses, strains, and forces in structures or components rotate around the pin which joins two rods. A knuckle joint is
caused by loads that do not induce significant inertia and understood to be a hinged joint in which projection in one part
damping effects. Steady loading and response conditions are enters the recess of the other part and two are held together by
assumed; that is, the loads and the structure's response are passing a pin through coaxial holes in two parts. This joint
assumed to vary slowly with respect to time. A static cannot sustain compressive force because of possible rotation
structural load can be performed using the ANSYS solver. about the pin. There are most common in steering and drive
The types of loading that can be applied in a static analysis train applications where it needs to move something but also
include: need to allow for offset angles. A knuckle joint is used when
two or more rods subjected to tensile and compressive forces
1) Externally applied forces and pressures.
are fastened together such that their axes are not in alignment
2) Steady-state inertial forces (such as gravity or
but meet in a point. This type of joint allows a small angular
rotational velocity).
movement of one rod relative to another. The joint can be
3) Imposed (nonzero) displacements.
easily connected and disconnected. Knuckle joint is found in
4) Temperatures (for thermal strain).
valve rods, braced girders, links of suspension chains, elevator
Static analysis of knuckle joint design is performed using
chains, etc. The knuckle joint assembly consists of following
ANSYS 16.0 to find the static deflection and stress for
major components:
corresponding pay load. The Static Analysis involves
following major steps.
 Single eye.

4.2. Pre-Processing  Double eye or fork.

 Geometry Modeling  Knuckle pin.

 Meshing Table.1.Specification of Knuckle joint.

 Material 1 Rod diameter b 40mm

 Contact Definition
2 Load applied P 50KN
 Loading and boundary condition
3 Diameter of knuckle pin 40mm
 Solution
(dp) = d, dp
4.3. Post-Processing
4 Thickness of single eye ( 1.25d = 1.25x40, b
 Deformation b) = 50mm
 Stresses

376
 Resincap Journal of Science and Engineering
Volume 2, Issue 5 May 2018
ISSN: 2456-9976

5 0.75d = 0.75x40, a convenient to select the free mesh because the has sharp
Thickness of fork (a) curves, so that shape of the object will not alter. To mesh the
= 30mm
plate the element type must be decided first. SOLID187 is
used here for meshing plates.
6 Outer diameter of eye 2d = 2x40, D =
(d1) 80mm 4.5.1 Solid187 Element Description
SOLID187 element is a higher order 3-D, 10-node element.
Table .2 Material Properties SOLID187 has a quadratic displacement behavior and is well
suited to modeling irregular meshes (such as those produced
Material Unit Structu AL Stainless Teflo Gray from various CAD/CAM systems).The element is defined by
10 nodes having three degrees of freedom at each node:
Property ral Steel n Iron
translations in the nodal x, y, and z directions. The element
Steel has plasticity, hyper elasticity, creep, stress stiffening, large
deflection, and large strain capabilities. It also has mixed
Modulus of GPa 200 71 193 0.5 110 formulation capability for simulating deformations of nearly
incompressible elastoplastic materials, and fully
Elasticity incompressible hyperplastic materials. The geometry, node
locations, and the coordinate system for this element are
Poisson‟s 0.3 0.27 0.31 .46 0.28 shown in Figure: SOLID187 Geometry. In addition to the
Ratio nodes, the element input data includes the orthotropic or
- anisotropic material properties. Orthotropic and anisotropic
material directions correspond to the element coordinate
directions.
Mass kg/ 7750 275 7750 2100 7200
Density m3 0

Material MPa 250 280 207 150 190

Strength

Fig.5.SOLID187 Geometry

4.5.2 Solid187 Assumptions and Restrictions

 The element must not have a zero volume.

 Elements may be numbered either as shown

Fig.3.FE Modeling details; Nodes: 33674, Elements:
191244
4.5. Meshing
Meshing involves division of the entire of model into small
pieces called elements. This is done by meshing. It is
in Figure: SOLID187 Geometry or may have node L
below the I, J, K plane.
 An edge with a removed midside node implies that the
displacement varies linearly, rather than parabolically,
along that edge. See Quadratic Elements (Midside

377
 Resincap Journal of Science and Engineering
Volume 2, Issue 5 May 2018
ISSN: 2456-9976

Nodes) in the Modeling and Meshing Guide for

information about using midside nodes.

 When mixed formulation is used (KEYOPT(6) = 1 or

2), no midside nodes can be missed.

 If you use the mixed formulation (KEYOPT(6) = 1 or

2), the damped eigensolver is not supported. You must
use the sparse solver (default).

Fig.7. Knuckle joint Model bc's

6. TOTAL DEFORMATION
Steel have observed less deformation compared o other
material. Apart from this AL material, also shows very low
deformation

Table No.3.Total Deformation

Total Deformation(mm)

Material Eye

Steel 0.053

AL 0.148

Stainless Steel 0.055

Teflon 20.537

CI 0.096

Fig.6. FE Modeling details; Nodes: 33674, Elements:
191244
5. LOADS AND BOUNDARY
CONDITIONS
Eye end is fixed in all directions and force is applied on fork
end. Below fig. shows loads and bc's knuckle joint. Same bc's
are applied for cases of material models.
7. EXPERIMENTAL WORK
A based FEA result, AL alloy material was proposed and
hence physical model of AL alloy mentioned below was
considered to prepare. The manufacturing of knuckle joint
was done at „FINE CASTING INTERPRISES‟. Refer below
snap for the industry details. AL Alloy material composition:
Grade 2024 was considered as per available in market.

378
 Resincap Journal of Science and Engineering
Volume 2, Issue 5 May 2018
ISSN: 2456-9976

The drawing of all three components was made in catia for The knuckle joint was made using sand casting process.
making pattern for casting process. Refer below drawing
details as below.
7.1. Sand Casting Process
Table.No.4. Result

Experimental ANSYS Percentage

Knuckle Joint Results Results Difference

Static Deformation(mm) 0.148 0.140 5%

Sand casting, the most widely used casting process, utilizes

expendable sand molds to form complex metal parts that can
be made of nearly any alloy. Because the sand mold must be
destroyed in order to remove the part, called the casting, sand
casting typically has a low production rate. The sand casting
process involves the use of a furnace, metal, pattern, and sand
mold. The metal is melted in the furnace and then ladled and
poured into the cavity of the sand mold, which is formed by
the pattern. The sand mold separates along a parting line and
the solidified casting can be removed.

7.2. Machining process

Machining is the broad term used to describe removal of
material from a workpiece, it covers several processes, which
we usually divide into the following categories:

• Cutting, generally involving single-point or

multipoint cutting tools, each with a clearly defined geometry.

• Abrasive processes, such as grinding.

• Nontraditional machining processes, utilizing

electrical, chemical, and optimal sources of energy.

379
 Resincap Journal of Science and Engineering
Volume 2, Issue 5 May 2018
ISSN: 2456-9976

It is important to view machining, as well as all 45000 0.1336 0.1246

manufacturing operations, as a system consisting of the work
piece, the tool and the machine. The introduction topic in this 50000 0.1484 0.1400
section covers primers on topics like mechanics & shear
bending in machining, and heat in machining. The traditional
machining includes primers on turning, milling, drilling, and
grinding. It also includes computer applications which are
being supported by the primers. The nontraditional machining
includes primers on the topics like ECM, EDM, AFM, USM.
The final job is the tested on UTM to calculate deformation of
joint for 50KN load. Below the industry certificate for
successfully completing manufacturing of knuckle joint.

7.3. Tensile Testing

7.3.1. Universal Testing Machine
A universal testing machine (UTM), also known as a
universal tester, materials testing machine or materials test
frame, is used to test the tensile strength and compressive
strength of materials. An earlier name for a tensile testing
machine is a tensometer. The "universal" part of the name
reflects that it can perform many standard tensile and
compression tests on materials, components, and structures (in
other words, that it is versatile).

8. RESULT Fig.8.Load Vs Delction Graph

Validation of FEA and Experimental results by correlating AL With current load of 50KN, the knuckle joint does cross yield
alloy deformation observed in FEA and comparing with point and hence graph showing linear behavior.
experimental measured deformation in tensile testing.
CONCLUSION
Knuckle joint was analysis for five different material.
Static deformation of AL allot knuckle joint was validated
with experimental. Good agreement is observed for
experimental measure static deformation in UTM and FEA
Table No.5. the load vs. deflection data from FEA and results. The results are validated and hence we can conclude
experimental. that the ANSYS results are reliable and can be applied for
complicated analysis.
FEA Experimental  Deformation of steel and AL material are very less co
pared to Teflon and CI.
Load(N) Deflection(mm)  Steel FOS are higher than min requirement of 3,
however the material cost and mass of steel is higher
5000 0.0148 0.0138 compared all other material.
 Material cost of Teflon is less compared all other
10000 0.0297 0.0277 material along with FOS and hence Teflon will not be
good material even having less mass.
 Steel and CI having similar FOS and mass of knuckle
15000 0.0445 0.0415 also seems comparative and hence both material were
not recommended.
20000 0.0594 0.0554  AL is having highest FOS and less mass compared to
steel and CI and hence based FEA study we
25000 0.0742 0.0692 recommended to manufacture knuckle joint in future
with AL material.
30000 0.0891 0.0831  AL material is sustaining tensile loading of 50KN
with min FOS of 3.5
35000 0.1039 0.0969 REFERENCES
[1] Evaluation of FEM based fracture mechanics
40000 0.1187 0.1107 technique to estimate life of an automotive forged
steel crankshaft of a single cylinder diesel engine

380
 Resincap Journal of Science and Engineering
Volume 2, Issue 5 May 2018
ISSN: 2456-9976

Rajesh M. Metkar, Vivek K. Sunnapwar , Subhash Crankshafts.” Journal of Applied Sciences 6 (3):
Deo Hiwase, Vidya Sagar Anki, Mahendra Dumpa 591-594, 2006.
, Procedia Engineering 51 ( 2013 ) 567 – 572.

[2] Yu Ding and Xiaobo Li.,2011, “ Crankshaft

Strength Analysis of a Diesel Engine Using Finite
Element Method,” Asia-Pacific Power and Energy
Engineering Conference.

[3] Jian Meng., Yongqi Liu., Ruixiang

Liu.,2011,“Finite Element Analysis of 4-
Cylinder Diesel Crankshaft, ” I.J. Image, Graphics
and Signal Processing, 5, 22-29.

[4] MENG Jian., LIU Yong-qi., LIU Rui-xiang., and

ZHENG Bin.,2011,“Intension Analysis of 3-D
Finite Element Analysis on 380 diesel crankshaft,”
International Conference on Computational and
Information Sciences.

[5] Yu Gongzh.i, Yu Hongliang., Duan Shulin., 2011,

“Crankshaft Dynamic Strength Analysis for Marine
Diesel Engine,” Third International Conference on
Measuring Technology and Mechatronics
Automation.

[6] Solanki, K. Tamboli,M.J, M.J, M.J, M.J.

Zinjuwadia, (2011), “Crankshaft Design and
Optimization- A Review” National Conference on
Recent Trends in Engineering & Technology.

[7] H. Montazersadgh, A. Fatemi, (2007), “Project

Report on Stress Analysis and Optimization of
Crankshafts Subject to Dynamic Loading” The
University of Toledo.

[8] Design ,Analysis and Optimization of a 6 cylinder

Engine Crank shaft Y V. Mallikarjuna Reddy1, T .
Vijaya Devi.

[9] Finite Element Analysis and Optimization of

Crankshaft Design Rinkle Garg, 2 Sunil Baghla.

[10] M. Balamurugan, R. Krishnaraj, M. Sakthivel, K.

Kanthavel, D. Marudachalam, R. Palani, (2011),
Computer Aided Modeling and Optimization of
Crankshaft” International Journal of Scientific &
Engineering Research, vol 2 , issue 8.

[11] Z. Guangming, J. Zhengfeng, (2009), “Study on

Torsional Stiffness of Engine Crankshaft”
International Forum on Computer Science
Technology and Applications,

[12] M.K.Paswan and A.K.Goel,(2008) “Fatigue Testing

procedure of 6 Cylinder Diesel Engine
Crakkshafts,” ARISER Vol.4 No.3(2008) 144-151.

[13] S.S.Mohtasebi, H.Afshari and H. Mobli,(2006)

“Analysis of Crankshafts Vibrations to compare the
Dynamic Behavior of Steel and Cast Iron

381