International Research Journal of Engineering and Technology (IRJET)
e-ISSN: 2395-0056
Volume: 11 Issue: 09 | Sep 2024
p-ISSN: 2395-0072
www.irjet.net
Design for Manufacturing and Assembly of a BAJA Steering Knuckle Claudimir Jose Rebeyka1, Guilherme Matheus Sviech Pontarolo2 , Marcelo Arceno2, Ravilson Antonio Chemin Filho1, Sérgio Fernando Lajarin1 1Professor, Department of Mechanical Engineering, Federal University of Parana. Brasil 2Student, Department of Mechanical Engineering, Federal University of Parana. Brasil
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Abstract: This study aims to demonstrate the application
arm suspension system used by the UFPR Baja SAE team, highlighting the steering knuckle along with some other components of the suspension.
of Design for Manufacturing and Assembly (DFMA) principles to the steering knuckle of the all-terrain Baja vehicle developed by the UFPR Baja SAE team. The steering knuckle typically presents challenges in manufacturing and assembly, often resulting in parts with incorrect dimensions and higher rate of scrap. To address these issues, DFMA concepts from the literature that are most applicable to the design of this component were selected and implemented in the redesign of the steering knuckle. As a result, a 33% reduction in the number of parts and a 6.49% reduction in part costs were achieved, leading to significant improvements in the assembly process, as well as in the subsequent mechanical adjustments and maintenance of the knuckle.
a)
Keywords: DFMA, steering knuckle, BAJA
b)
Figure 1: Steering knuckle a) project; b) as built
1. INTRODUCTION
Figure 1 presents: a) the current design of the steering knuckle for the UFPR Baja SAE prototype, and b) the manufactured version. The project encountered manufacturing and assembly difficulties, as reported by the manufacturing team. Several parts had to be discarded due to manufacturing non-conformities, wich rendered them incompatible for assembly.
The Baja SAE BRASIL program presents a challenge to engineering students, providing them the opportunity to apply classroom knowledge obtained in a practical envorinment, thereby enhancing their preparation for the job market. (SAEBRASIL, 2022) In this context, the design of components used in the Baja vehicle prototype must consider criteria such as efficiency for competitiveness, cost-effectiveness, manufacturing and assembly feasability, among other desired characteristics typical of competition and series production vehicles. To achieve this, methodologies such as Design for Manufacturing and Assembly (DFMA) are particulary relevant, as they are used to optimize designs focusing on manufacturing and assembly processes. This methodology is grounded in concepts and criteria at streamlining, simplifying, and reducing costs in product development. (BERTIN, 2019)
2. DESIGN FOR MANUFACTURING AND ASSEMBLY DFMA is a methodology applied in product design to optimize manufacturing and assembly processes. (BOOTHROYD, DEWHURST, KNIGHT, 2011). It is primarly divided into three main applications: supplier costing, product costing, and product simplification (Figure 2). The focus of product simplification shifts from individual componentes to the product as a whole. By simplifying the overall design, the number of parts is reduced, leading to a decrease in overall costs. (DEWHURST, 2019)
1.1 Steering knuckle The steering knuckle was selected for the application of DFMA in the Baja project due to its relative complexity in manufacturing and assembly. The steering knuckle is a key component that connects the suspension to the vehicle's wheel. Figure 1 ilustrates the assembly of the Double A-
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