Trade-off design between lightweight, high rigidity and vibration transmission characteristics by casting automobile chassis parts using iron mold

Abstract

Automobile chassis parts such as steering knuckles require high strength and are therefore cast in one piece, eliminating the need of joint. Achieving light weight and high rigidity requires a three-dimensional shape design that enhances structural strength, however it is difficult to produce structures such as 2mm thick ribs using current sand casting methods. It is known that sound and vibration performance generally deteriorates as weight is reduced, resulting in a trade-off with fuel economy. In this study, we attempt a new method of casting using molds to examine a design that can achieve both light weight and high rigidity as well as improved sound and vibration performance by removing the primary resonance frequency from the road noise frequency range. In a design results in this stduy shows a capability to escape the main resonance frequency from the road noise frequency range.