Feasibility study on the application of high strength ductile iron to automotive chassis parts

To study the feasibility of high strength ductile iron to chassis parts, the steering knuckle for which high strength and very high functional safety level are required was selected for the case study part. As the result of the optimum casting design obtained through detailed design examination and stress analysis by using urethane models, and the full utilization of high shape accommodativity of the castings, it is proved that both the weight and cost of the cast knuckle can be reduced by 20% with the same fatigue strength comparing with the current forged one. Results of all tests including impact strength test and vehicle test clearly promise the positive prospect of its practical application.