Additive biomimetic steering knuckle and its manufacturing method, vehicle

Abstract

This invention provides an additive biomimetic steering knuckle, its manufacturing method, and a vehicle. The additive biomimetic steering knuckle includes a steering knuckle body with bearing holes. The steering knuckle body is connected to a wheel hub bearing through these bearing holes. Along the circumference of the steering knuckle body, a brake caliper mounting portion, an upper control arm mounting portion, a toe-in arm mounting portion, and a trapezoidal arm mounting portion are sequentially arranged to connect the steering knuckle body to at least one of the brake caliper, upper control arm, toe-in arm, and trapezoidal arm. The steering knuckle body has multiple weight-reducing holes and multiple reinforcing rib structures. The steering knuckle body is manufactured using additive manufacturing technology. By applying the technical solution of this invention, the steering knuckle is manufactured using additive manufacturing technology and equipped with weight-reducing holes and reinforcing rib structures. While achieving the performance and functional requirements of the original casting solution in the same application scenario, unnecessary materials are eliminated, achieving the goal of lightweight design.

Description

Technical Field

[0001] This invention relates to the field of automotive chassis design, and more specifically, to an additive biomimetic steering knuckle, its manufacturing method, and a vehicle. Background Technology

[0002] The steering knuckle is a crucial structural component in a car chassis. As an important part of the suspension system, its main function is to connect the various control arms, wheel bearings, and calipers, transmitting forces and torques, and cooperating with other structural components to perform functions such as steering and wheel hop. The steering knuckle bears the forces and torques from the control arms, brake calipers, and wheel bearings, and experiences high alternating loads during vehicle operation. Furthermore, due to the requirements of suspension kinematic control, the steering knuckle cannot easily deform, which necessitates a certain level of rigidity. Therefore, structurally, the steering knuckle possesses high strength, rigidity, and durability. Since the steering knuckle is unsprung, an increase in its weight directly leads to an increase in unsprung mass, which reduces vehicle handling and comfort.

[0003] Currently available steering knuckles can be divided into four types based on their manufacturing process:

[0004] 1) Cast iron steering knuckle: Suitable for passenger cars, it can be used to cast products with complex cross-sectional shapes. Compared with cast aluminum, it has higher material properties and lower cost. The disadvantage is that it is heavy and its application is becoming less and less common.

[0005] 2) Forged steel steering knuckles: Less commonly used in passenger cars, but widely used in commercial vehicles. Compared to cast iron steering knuckles, they have superior material properties, resulting in better weight reduction. The disadvantage is higher cost.

[0006] 3) Solid cast aluminum steering knuckles: Widely used in passenger vehicles, these knuckles can be cast to produce complex cross-sectional shapes. Due to the lightweight advantages of aluminum alloys, they can reduce weight by approximately 30% compared to cast iron steering knuckles, making them the most widely used process in the passenger vehicle industry. The disadvantage is that the cost is 50% higher than that of iron materials.

[0007] 4) Forged aluminum steering knuckle: Suitable for passenger cars. Compared with solid cast aluminum steering knuckle, the material performance is improved by 20% and the weight is reduced by about 5-8%. The disadvantage is that the cost increases by 70% and the molding complexity is not as good as solid casting. It can only be molded into a relatively flat structure.

[0008] In summary, traditionally cast or forged steering knuckles are limited by numerous process constraints, such as draft angle, feeding channels, venting, cooling, positioning platform, and ejection platform. This results in the presence of some material that is "useless" in terms of load-bearing capacity. This "useless" material increases the weight of the part, thereby reducing vehicle handling and comfort, and affecting the vehicle's driving range.

[0009] There is currently no effective solution to the technical problem of how to achieve lightweight steering knuckles while maintaining their strength, rigidity, and durability. Summary of the Invention

[0010] The main objective of this invention is to provide an additive biomimetic steering knuckle, its manufacturing method, and a vehicle thereof, so as to solve the problem of achieving lightweight steering knuckles while maintaining their strength, rigidity, and durability in the prior art.

[0011] To achieve the above objectives, according to one aspect of the present invention, an additive biomimetic steering knuckle is provided, comprising: a steering knuckle body, a bearing hole provided on the steering knuckle body, the steering knuckle body being connected to a wheel hub bearing through the bearing hole, and a brake caliper mounting portion, an upper control arm mounting portion, a toe arm mounting portion, and a trapezoidal arm mounting portion being sequentially arranged along the circumference of the steering knuckle body, so that the steering knuckle body is connected to at least one of the brake caliper, the upper control arm, the toe arm, and the trapezoidal arm; the steering knuckle body is provided with a plurality of weight-reducing holes and a plurality of reinforcing rib structures; the steering knuckle body is manufactured using an additive manufacturing process.

[0012] Furthermore, the steering knuckle body has a first surface and a second surface that are disposed opposite to each other. The steering knuckle body also has a circumferential side surface for connecting the first surface and the second surface. A connecting rod mounting part is provided on the steering knuckle body. The connecting rod mounting part is used to connect the trapezoidal arm connecting rod. The connecting rod mounting part protrudes from the first surface and is located near the trapezoidal arm mounting part and the brake caliper mounting part.

[0013] Furthermore, the weight-reducing holes are arranged along the axial or radial direction of the steering knuckle body, and at least one reinforcing rib structure is provided between at least two adjacent weight-reducing holes.

[0014] Furthermore, the weight-reducing holes include: a first weight-reducing hole, which is formed on a first surface, and there are multiple first weight-reducing holes, with at least a portion of the first weight-reducing holes located near the toe-in arm mounting portion, at least a portion of the first weight-reducing holes located near the trapezoidal arm mounting portion, and at least a portion of the first weight-reducing holes located near the brake caliper mounting portion; and a second weight-reducing hole, which is formed on a circumferential side surface, and there are multiple second weight-reducing holes, with at least a portion of the second weight-reducing holes located between the brake caliper mounting portion and the trapezoidal arm mounting portion, at least a portion of the second weight-reducing holes located near the trapezoidal arm mounting portion, and at least a portion of the second weight-reducing holes distributed circumferentially along the bearing holes.

[0015] Furthermore, the reinforcing rib structure includes: a first reinforcing rib structure, which includes multiple intersecting reinforcing ribs and is disposed on a first surface; a second reinforcing rib structure, which includes multiple second reinforcing ribs and is disposed on a circumferential side surface, between the brake caliper mounting portion and the trapezoidal arm mounting portion, extending along the axial direction of the steering knuckle body; and a third reinforcing rib structure, which includes multiple third reinforcing ribs and is disposed on a circumferential side surface, extending from the brake caliper mounting portion to the connecting rod mounting portion.

[0016] Furthermore, multiple dust baffle mounting holes are provided on the second surface, and the steering knuckle body is connected to the dust baffle through the dust baffle mounting holes. Wiring harness bracket mounting holes and sensor mounting holes are also provided on the circumferential side, and the steering knuckle body is connected to the metal wiring harness bracket through the wiring harness bracket mounting holes and the steering knuckle body is connected to the wheel speed sensor through the sensor mounting holes.

[0017] Furthermore, a boss is provided on the second surface, which is arranged circumferentially around the bearing hole. Multiple mounting holes are provided on the boss, which are evenly arranged circumferentially around the bearing hole. A drain groove and multiple stress grooves are also provided on the boss, which are distributed circumferentially around the bearing hole. One end of the drain groove is located close to the bearing hole, and the other end of the drain groove is connected to at least one weight reduction hole.

[0018] Furthermore, there are three stress grooves and one drain groove. The three stress grooves and the drain groove are arranged at intervals along the circumference of the bearing hole. The drain groove is connected to the second weight reduction hole located near the trapezoidal arm mounting part.

[0019] According to another aspect of the present invention, a method for manufacturing an additive biomimetic steering knuckle is provided. The manufacturing method is used to manufacture the above-mentioned additive biomimetic steering knuckle, and the manufacturing method includes the following steps: S1, designing the largest solid as the design space based on the steering knuckle arrangement space and motion space; S2, performing topology optimization based on load conditions, using a stiffness-based topology algorithm to obtain 3D data after topology optimization; S3, performing biomimetic design on the topology results; S4, reconstructing complex curved surfaces based on the biomimetic design results to improve the consistency of surface shapes; S5, designing connecting holes and connecting planes for the reconstructed steering knuckle model; S6, performing CAE finite element analysis to verify whether the strength, stiffness, and durability of the steering knuckle model meet the requirements, and if they do, proceeding to step S7; S7, performing a manufacturing feasibility analysis on the steering knuckle model, and if the manufacturing feasibility is met, proceeding to step S8; S8, manufacturing the steering knuckle using additive manufacturing technology based on the steering knuckle model.

[0020] According to another aspect of the present invention, a vehicle is provided having an additive bionic steering knuckle, wherein the additive bionic steering knuckle is the additive bionic steering knuckle described above.

[0021] By applying the technical solution of this invention, the steering knuckle is manufactured through additive manufacturing process and equipped with weight-reducing holes and reinforcing ribs. While achieving the performance and functional requirements of the original casting solution in the same application scenario, useless materials are removed, thus achieving the goal of lightweight design. Attached Figure Description

[0022] The accompanying drawings, which form part of this application, are used to provide a further understanding of the invention. The illustrative embodiments of the invention and their descriptions are used to explain the invention and do not constitute an undue limitation of the invention. In the drawings:

[0023] Figure 1 A schematic diagram of the structure of a first embodiment of the additive biomimetic steering knuckle according to the present invention is shown;

[0024] Figure 2 A schematic diagram of a second embodiment of the additive biomimetic steering knuckle according to the present invention is shown;

[0025] Figure 3 A schematic diagram of a third embodiment of the additive biomimetic steering knuckle according to the present invention is shown;

[0026] Figure 4 A schematic diagram of a fourth embodiment of the additive biomimetic steering knuckle according to the present invention is shown;

[0027] Figure 5 A schematic diagram of the structure of a fifth embodiment of the additive biomimetic steering knuckle according to the present invention is shown;

[0028] Figure 6 A schematic diagram of a sixth embodiment of the additive biomimetic steering knuckle according to the present invention is shown.

[0029] The above figures include the following reference numerals:

[0030] 100. Steering knuckle body;

[0031] 1. Bearing bore; 2. Mounting hole;

[0032] 3. Brake caliper mounting section;

[0033] 4. Upper control arm mounting section;

[0034] 5. Connecting rod mounting section;

[0035] 6. Trapezoidal arm mounting section;

[0036] 7. Dust baffle mounting holes;

[0037] 8. Sewage drain;

[0038] 9. Wiring harness bracket mounting holes;

[0039] 10. Sensor mounting holes;

[0040] 11. Stress groove;

[0041] 12. Front toe arm mounting section;

[0042] 21. First reinforcing rib structure; 22. Second reinforcing rib structure; 23. Third reinforcing rib structure;

[0043] 31. First weight reduction hole; 32. Second weight reduction hole. Detailed Implementation

[0044] It should be noted that, unless otherwise specified, the embodiments and features described in this application can be combined with each other. The present invention will now be described in detail with reference to the accompanying drawings and embodiments.

[0045] It should be noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the exemplary embodiments according to this application. As used herein, the singular form is intended to include the plural form as well, unless the context clearly indicates otherwise. Furthermore, it should be understood that when the terms "comprising" and / or "including" are used in this specification, they indicate the presence of features, steps, operations, devices, components, and / or combinations thereof.

[0046] It should be noted that the terms "first," "second," etc., in the specification, claims, and accompanying drawings of this application are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. It should be understood that such terms can be used interchangeably where appropriate so that the embodiments of this application described herein can be implemented, for example, in orders other than those illustrated or described herein. Furthermore, the terms "comprising" and "having," and any variations thereof, are intended to cover a non-exclusive inclusion; for example, a process, method, system, product, or apparatus that comprises a series of steps or units is not necessarily limited to those steps or units explicitly listed, but may include other steps or units not explicitly listed or inherent to such processes, methods, products, or apparatus.

[0047] Exemplary embodiments according to this application will now be described in more detail with reference to the accompanying drawings. However, these exemplary embodiments may be implemented in many different forms and should not be construed as being limited to the embodiments set forth herein. It should be understood that these embodiments are provided so that the disclosure of this application is thorough and complete, and that the concept of these exemplary embodiments is fully conveyed to those skilled in the art. In the drawings, for clarity, the thickness of layers and regions may be exaggerated, and the same reference numerals are used to denote the same devices, and therefore their description will be omitted.

[0048] Combination Figures 1 to 6 As shown, according to a specific embodiment of this application, an additive bionic steering knuckle is provided.

[0049] Specifically, the additive bionic steering knuckle includes a steering knuckle body 100, on which a bearing hole 1 is provided. The steering knuckle body 100 is connected to the wheel hub bearing through the bearing hole 1. A brake caliper mounting part 3, an upper control arm mounting part 4, a toe arm mounting part 12, and a trapezoidal arm mounting part 6 are arranged sequentially along the circumference of the steering knuckle body 100, so that the steering knuckle body 100 can be connected to at least one of the brake caliper, upper control arm, toe arm, and trapezoidal arm. The steering knuckle body 100 is provided with multiple weight-reducing holes and multiple reinforcing rib structures. The steering knuckle body 100 is manufactured using additive manufacturing technology.

[0050] By applying the technical solution of this embodiment, the steering knuckle is manufactured using additive manufacturing technology and equipped with weight-reducing holes and reinforcing ribs. While achieving the performance and functional requirements of the original casting solution for the same application scenarios, unnecessary materials are eliminated, achieving the goal of lightweight design. In this embodiment, the additive biomimetic steering knuckle is made of aluminum alloy powder (AlMgSc).

[0051] The explanation of additive manufacturing technology is as follows: Additive manufacturing is a technology that uses a gradual accumulation of material to create solid parts. Compared to traditional material removal-cutting technology, it is a "bottom-up" manufacturing method. In the past two decades, additive manufacturing technology has developed rapidly, and various names such as "rapid prototyping," "3D printing," and "free-form manufacturing" express the characteristics of this technology from different perspectives.

[0052] In one exemplary embodiment of this application, the brake caliper mounting portion 3 has two mounting holes, the upper control arm mounting portion 4 is a double-ear structure protruding radially along the steering knuckle body 100, with mounting holes arranged circumferentially along the steering knuckle body 100 on the double-ear structure, the toe-in arm mounting portion 12 has mounting holes arranged circumferentially along the steering knuckle body 100, and the trapezoidal arm mounting portion 6 is a double-ear structure protruding radially along the steering knuckle body 100, with mounting holes arranged circumferentially along the steering knuckle body 100 on the double-ear structure. The additive bionic steering knuckle in this embodiment is suitable for connecting trapezoidal arms in the rear suspension of passenger vehicles.

[0053] Specifically, the steering knuckle body 100 has a first surface and a second surface disposed opposite to each other. The steering knuckle body 100 also has a circumferential side surface for connecting the first surface and the second surface. A connecting rod mounting portion 5 is provided on the steering knuckle body 100. The connecting rod mounting portion 5 is used to connect the trapezoidal arm connecting rod. The connecting rod mounting portion 5 protrudes from the first surface and is located near the trapezoidal arm mounting portion 6 and the brake caliper mounting portion 3. By providing the connecting rod mounting portion 5, the connection between the trapezoidal arm and the steering knuckle is made more stable.

[0054] In one exemplary embodiment of this application, the connecting rod mounting portion 5 is provided with a mounting hole parallel to the radial direction of the steering knuckle body 100. Optionally, the radial cross-sectional area of ​​the steering knuckle body 100 is provided to gradually increase from the second surface to the first surface.

[0055] Furthermore, the weight-reducing holes are arranged along the axial or radial direction of the steering knuckle body 100, and at least one reinforcing rib structure is provided between at least two adjacent weight-reducing holes. The weight-reducing holes can effectively reduce the weight of the steering knuckle body 100 itself, realizing lightweight design, and the reinforcing rib structure can enhance the strength of the steering knuckle body 100 itself, so that the weight reduction can be achieved while ensuring the strength requirements of the steering knuckle body 100, thus ensuring the normal use of the steering knuckle.

[0056] Specifically, the weight reduction holes include a first weight reduction hole 31 and a second weight reduction hole 32. The first weight reduction hole 31 is formed on the first surface, and there are multiple first weight reduction holes 31. At least a portion of the first weight reduction holes 31 are located near the toe-in arm mounting portion 12, at least a portion of the first weight reduction holes 31 are located near the trapezoidal arm mounting portion 6, and at least a portion of the first weight reduction holes 31 are located near the brake caliper mounting portion 3. The second weight reduction hole 32 is formed on the circumferential side, and there are multiple second weight reduction holes 32. At least a portion of the second weight reduction holes 32 are formed between the brake caliper mounting portion 3 and the trapezoidal arm mounting portion 6, at least a portion of the second weight reduction holes 32 are located near the trapezoidal arm mounting portion 6, and at least a portion of the second weight reduction holes 32 are distributed circumferentially along the bearing hole 1.

[0057] It should be noted that, while ensuring structural strength, the steering knuckle body 100 can also be equipped with more weight-reducing holes in different locations to further reduce the weight of the steering knuckle. The shape, size, and position of the weight-reducing holes can all be adjusted as needed.

[0058] Specifically, the reinforcing rib structure includes a first reinforcing rib structure 21, a second reinforcing rib structure 22, and a third reinforcing rib structure 23. The first reinforcing rib structure 21 includes multiple intersecting reinforcing ribs and is disposed on the first surface. The second reinforcing rib structure 22 includes multiple reinforcing ribs and is disposed on the circumferential side surface. The second reinforcing rib structure 22 is disposed between the brake caliper mounting part 3 and the trapezoidal arm mounting part 6 and extends along the axial direction of the steering knuckle body 100. The third reinforcing rib structure 23 includes multiple reinforcing ribs and is disposed on the circumferential side surface. The third reinforcing rib structure 23 extends from the brake caliper mounting part 3 to the connecting rod mounting part 5.

[0059] In this embodiment, the first reinforcing rib structure 21 is a cross structure, and at least a portion of the first reinforcing rib structure 21 is located between the weight-reducing holes, which can effectively enhance the structural strength. The second reinforcing rib structure 22 is a radial structure, extending along the force direction of the steering knuckle, which can facilitate the force distribution of the steering knuckle. The third reinforcing rib structure 23 extends from the brake caliper mounting part 3 to the connecting rod mounting part 5, which can enhance the structural stability of the connecting rod mounting part 5. It should be noted that more reinforcing rib structures can be provided on the steering knuckle body 100 to improve the structural strength.

[0060] Furthermore, multiple dust baffle mounting holes 7 are provided on the second surface. The steering knuckle body 100 is connected to the dust baffle through the dust baffle mounting holes 7. A wiring harness bracket mounting hole 9 and a sensor mounting hole 10 are also provided on the circumferential side. The steering knuckle body 100 is connected to the metal wiring harness bracket through the wiring harness bracket mounting hole 9, and the steering knuckle body 100 is connected to the wheel speed sensor through the sensor mounting hole 10.

[0061] By providing the dust baffle mounting hole 7 to connect with the dust baffle, the impact of external dust on the steering knuckle can be reduced. The sensor mounting hole 10, connected with the wheel speed sensor, facilitates wheel speed detection and integrates multiple components on the steering knuckle. The wiring harness bracket mounting hole 9 facilitates routing.

[0062] Furthermore, a boss is provided on the second surface, circumferentially surrounding the bearing hole 1. Multiple mounting holes 2 are formed on the boss, evenly arranged circumferentially around the bearing hole 1. A drain groove 8 and multiple stress grooves 11 are also formed on the boss, distributed circumferentially around the bearing hole 1. One end of the drain groove 8 is located close to the bearing hole 1, and the other end communicates with at least one weight-reducing hole. The mounting holes 2 can be used for mounting bolts to fix the wheel hub bearing passing through the bearing hole 1 to the steering knuckle body 100. The drain groove 8 and multiple stress grooves 11 improve the load-bearing capacity of the steering knuckle body 100 while draining impurities such as water and sand, ensuring normal operation.

[0063] In the exemplary embodiment of this application, the boss has a square structure, and three stress grooves 11 and a drain groove 8 are respectively located on the four sides of the square boss. There are four mounting holes 2, which are respectively located at the four corners of the boss.

[0064] Preferably, there are three stress grooves 11 and one drain groove 8. The three stress grooves 11 and the drain groove 8 are arranged at intervals along the circumference of the bearing hole 1. The drain groove 8 is connected to the second weight reduction hole 32 located near the trapezoidal arm mounting part 6.

[0065] Multiple stress grooves 11 can distribute the force in multiple directions, making the vehicle drive more smoothly and reducing abnormal noises when turning on the spot. The drain trough 8 can be used to drain water, sand, gravel and other impurities to avoid damage to the steering knuckle structure and affect subsequent normal operation. For easy drainage, the drain trough 8 should be located at a low position. The drain trough 8 is connected to the second weight reduction hole 32 located near the trapezoidal arm mounting part 6, which can make the discharge of impurities smoother.

[0066] According to another specific embodiment of this application, a method for manufacturing an additive biomimetic steering knuckle is also provided. The manufacturing method is used to manufacture the above-mentioned additive biomimetic steering knuckle, and the manufacturing method includes the following steps:

[0067] S1, based on the steering knuckle arrangement space and motion space, the largest solid is designed as the space for the design;

[0068] S2, perform topology optimization based on load conditions. The topology algorithm is a stiffness-based topology algorithm, and obtain the topology-optimized 3D data.

[0069] S3, biomimetic design of the topology results;

[0070] S4, based on the design results of biomimetic design, reconstructs complex curved surfaces, making the surface shape more consistent;

[0071] S5, for the reconstructed steering knuckle model, design the connection holes and connection planes;

[0072] S6. Perform CAE finite element analysis to verify whether the strength, stiffness, and durability of the steering knuckle model meet the requirements. If the requirements are met, proceed to step S7.

[0073] S7. Perform a manufacturing feasibility analysis on the steering knuckle model. If the manufacturing feasibility is met, proceed to step S8.

[0074] The S8 uses an additive manufacturing process to manufacture the steering knuckle, based on a steering knuckle model.

[0075] By using S1-S8, a steering knuckle that meets the requirements for strength, rigidity, and connection of various components can be obtained, while effectively reducing the weight of the steering knuckle, thus achieving a lightweight design for the steering knuckle.

[0076] According to another specific embodiment of this application, a vehicle is also provided, the vehicle having an additive bionic steering knuckle, the additive bionic steering knuckle being the additive bionic steering knuckle described above.

[0077] According to another specific embodiment of this application, a preferred embodiment of an additively manufactured steering knuckle with a biomimetic structure and its manufacturing method is also provided, applicable to the trapezoidal arm form of passenger vehicle rear suspension. Traditionally cast or forged steering knuckles are limited by numerous process constraints such as draft angle, feeding channels, venting, cooling, positioning platform, and ejection platform, resulting in the presence of some "useless" material in the parts. This "useless" material is a significant cause of increased part weight. This embodiment, through part stress analysis and topology optimization, combined with biomimetic design principles and structural reconstruction, employs additive manufacturing processes to achieve the performance and functional requirements of the original casting solution while eliminating 30% of the useless material, thus achieving the goal of extreme lightweight design.

[0078] Specifically, the main connection structures and mating surfaces of the additively manufactured steering knuckle include: bearing hole 1 for connecting the third-generation bearing (i.e., wheel hub bearing); mounting holes 2 for four fixed bearings; caliper fixing holes for connecting to the brake caliper; lug structure for connecting to the upper control arm; connecting rod mounting part 5 for connecting to the trapezoidal arm link; lug structure for connecting to the trapezoidal arm; three dust disc mounting holes 7 for connecting to the dust disc; a drain trough 8; wiring harness bracket mounting holes 9; sensor mounting holes 10; stress groove 11 for reducing steering noise when stationary; and toe-in arm connection holes. Mounting hole 2 is a smooth bolt hole; dust disc mounting hole 7 is a threaded hole; drain trough 8 is used for draining water and removing sand and gravel; wiring harness bracket mounting hole 9 is used for installing a metal wiring harness bracket; and sensor mounting hole 10 is connected to the wheel speed sensor.

[0079] The main weight reduction design and biomimetic structural design include: weight reduction holes near the toe arm connection hole, weight reduction holes near the trapezoidal arm connection lug, weight reduction holes near the caliper connection point, weight reduction holes on the side body, and weight reduction holes distributed near the bearing holes.

[0080] The main load-bearing structure and reinforcing structure include: a multi-branched first reinforcing rib structure 21, which has a spiderweb-like distribution and can effectively transfer loads, release stress, and bear forces and moments. A jungle-like second reinforcing rib structure 22 can bear the main forces and moments on the sides, ensuring the strength and stiffness of the structure. The second reinforcing rib structure 22, arranged directly along the direction of force, can directly feed the stress state back to the structure, achieving optimal lightweighting.

[0081] The manufacturing method is as follows: First, design the largest solid as the design space based on the steering knuckle layout and movement space. Second, perform topology optimization based on load conditions using a stiffness-based topology algorithm to obtain the topologically optimized 3D data. Third, use CATIA software to perform biomimetic design on the topology results. Fourth, import the design results into Inspire software to reconstruct complex surfaces, improving surface shape consistency. Fifth, import the reconstructed shape into CATIA to design the connection holes and connection planes. Sixth, perform CAE finite element analysis to verify whether the strength, stiffness, and durability meet the requirements. If not, repeat the biomimetic design; if so, proceed to the next step. Seventh, perform a manufacturing feasibility analysis on the shape. If manufacturing feasibility is not met, repeat the biomimetic design; if it is, proceed to the next step. Finally, the design is complete.

[0082] Topology optimization is predicated on determining the materials and loads. In this embodiment, the material selected is aluminum alloy powder AlMgSc used for additive manufacturing, and the load is the load derived from the disassembly of the entire vehicle, which varies from vehicle to vehicle.

[0083] In this embodiment, the biomimetic structure includes a weight-reducing hole design, mesh reinforcement ribs, and a main structure for responsive force and transmission paths. This type of structure eliminates excess material, effectively and directly participates in the transmission of force and torque, ensuring the strength and rigidity of the parts, and giving them adequate durability. It is key to achieving lightweight design. The additive manufacturing method for biomimetic structures is applicable to trapezoidal arm rear suspension steering knuckles and can also be extended to steering knuckles, control arms, subframes, and other chassis structural components in other suspension types. This embodiment achieves a 30% weight reduction while maintaining the functionality of the original cast aluminum steering knuckle.

[0084] For ease of description, spatial relative terms such as "above," "on top of," "on the upper surface of," "above," etc., are used herein to describe the spatial positional relationship of a device or feature as shown in the figures to other devices or features. It should be understood that spatial relative terms are intended to encompass different orientations in use or operation beyond the orientation of the device as described in the figures. For example, if the device in the figures were inverted, a device described as "above" or "on top of" other devices or structures would subsequently be positioned as "below" or "under" other devices or structures. Thus, the exemplary term "above" can include both "above" and "below." The device may also be positioned in other different ways (rotated 90 degrees or in other orientations), and the spatial relative descriptions used herein will be interpreted accordingly.

[0085] In addition to the above, it should be noted that the terms "one embodiment," "another embodiment," and "embodiment" used in this specification refer to specific features, structures, or characteristics described in connection with that embodiment, which are included in at least one embodiment described in the general description of this application. The appearance of the same expression in multiple places in the specification does not necessarily refer to the same embodiment. Furthermore, when a specific feature, structure, or characteristic is described in connection with any embodiment, the intention is to suggest that implementing such a feature, structure, or characteristic in conjunction with other embodiments also falls within the scope of this invention.

[0086] In the above embodiments, the descriptions of each embodiment have different focuses. For parts not described in detail in a certain embodiment, please refer to the relevant descriptions in other embodiments.

[0087] The above description is merely a preferred embodiment of the present invention and is not intended to limit the invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. An additive biomimetic steering knuckle, characterized in that, include: The steering knuckle body (100) has a bearing hole (1) on it. The steering knuckle body (100) is connected to the wheel hub bearing through the bearing hole (1). A brake caliper mounting part (3), an upper control arm mounting part (4), a toe arm mounting part (12), and a trapezoidal arm mounting part (6) are arranged sequentially along the circumference of the steering knuckle body (100) so that the steering knuckle body (100) can be connected to at least one of the brake caliper, upper control arm, toe arm, and trapezoidal arm. The steering knuckle body (100) is provided with multiple weight reduction holes and multiple reinforcing rib structures. The steering knuckle body (100) is manufactured using additive manufacturing technology; The steering knuckle body (100) has a first surface and a second surface disposed opposite to each other, and the steering knuckle body (100) also has a circumferential side surface for connecting the first surface and the second surface; The weight reduction hole includes: The first weight reduction hole (31) is formed on the first surface. There are multiple first weight reduction holes (31). At least a portion of the first weight reduction holes (31) are located near the toe-in arm mounting portion (12), at least a portion of the first weight reduction holes (31) are located near the trapezoidal arm mounting portion (6), and at least a portion of the first weight reduction holes (31) are located near the brake caliper mounting portion (3). The second weight reduction hole (32) is opened on the circumferential side. There are multiple second weight reduction holes (32). At least a portion of the second weight reduction holes (32) are opened between the brake caliper mounting part (3) and the trapezoidal arm mounting part (6). At least a portion of the second weight reduction holes (32) are set close to the trapezoidal arm mounting part (6). At least a portion of the second weight reduction holes (32) are distributed circumferentially along the bearing hole (1).

2. The additive bionic steering knuckle according to claim 1, characterized in that, The steering knuckle body (100) is provided with a connecting rod mounting part (5), which is used to connect the trapezoidal arm connecting rod. The connecting rod mounting part (5) protrudes from the first surface and is located near the trapezoidal arm mounting part (6) and the brake caliper mounting part (3).

3. The additive bionic steering knuckle according to claim 1, characterized in that, The weight-reducing holes are arranged along the axial or radial direction of the steering knuckle body (100), and at least one of the reinforcing rib structures is provided between at least two adjacent weight-reducing holes.

4. The additive bionic steering knuckle according to claim 2, characterized in that, The reinforcing rib structure includes: The first reinforcing rib structure (21) includes a plurality of intersecting reinforcing ribs and is disposed on the first surface; The second reinforcing rib structure (22) includes multiple second reinforcing rib structures (22), the second reinforcing rib structure (22) is disposed on the circumferential side, the second reinforcing rib structure (22) is disposed between the brake caliper mounting part (3) and the trapezoidal arm mounting part (6), and the second reinforcing rib structure (22) extends along the axial direction of the steering knuckle body (100); The third reinforcing rib structure (23) is multiple, and the third reinforcing rib structure (23) is disposed on the circumferential side surface. The third reinforcing rib structure (23) extends from the brake caliper mounting part (3) to the connecting rod mounting part (5).

5. The additive bionic steering knuckle according to claim 2, characterized in that, Multiple dust baffle mounting holes (7) are provided on the second surface. The steering knuckle body (100) is connected to the dust baffle through the dust baffle mounting holes (7). The circumferential side is also provided with a wire harness bracket mounting hole (9) and a sensor mounting hole (10). The steering knuckle body (100) is connected to the metal wire harness bracket through the wire harness bracket mounting hole (9). The steering knuckle body (100) is connected to the wheel speed sensor through the sensor mounting hole (10).

6. The additive bionic steering knuckle according to claim 1, characterized in that, The second surface is provided with a boss, which is arranged around the bearing hole (1) in the circumference. The boss is provided with a plurality of mounting holes (2), which are evenly arranged along the circumference of the bearing hole (1). The boss is also provided with a drain groove (8) and a plurality of stress grooves (11), which are distributed along the circumference of the bearing hole (1). One end of the drain groove (8) is located close to the bearing hole (1), and the other end of the drain groove (8) is connected to at least one of the weight reduction holes.

7. The additive bionic steering knuckle according to claim 6, characterized in that, There are three stress grooves (11) and one drain groove (8). The three stress grooves (11) and the drain groove (8) are arranged circumferentially along the bearing hole (1). The drain groove (8) is connected to the second weight reduction hole (32) provided near the trapezoidal arm mounting part (6).

8. A method for manufacturing an additive biomimetic steering knuckle, characterized in that, The manufacturing method is used to manufacture the additive biomimetic steering knuckle according to any one of claims 1-7, and the manufacturing method includes the following steps: S1, based on the steering knuckle arrangement space and motion space, the largest solid is designed as the space for the design; S2, perform topology optimization based on load conditions. The topology algorithm is a stiffness-based topology algorithm, and obtain the topology-optimized 3D data. S3, biomimetic design of the topology results; S4, based on the design results of biomimetic design, reconstructs complex curved surfaces, making the surface shape more consistent; S5, for the reconstructed steering knuckle model, design the connection holes and connection planes; S6. Perform CAE finite element analysis to verify whether the strength, stiffness, and durability of the steering knuckle model meet the requirements. If the requirements are met, proceed to step S7. S7. Perform a manufacturing feasibility analysis on the steering knuckle model. If the manufacturing feasibility is met, proceed to step S8. The S8 uses an additive manufacturing process to manufacture the steering knuckle, based on a steering knuckle model.

9. A vehicle, characterized in that, The vehicle has an additive bionic steering knuckle, which is the additive bionic steering knuckle according to any one of claims 1-7.

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