The objective of this study is to analyze the difference between the theoretically calculated torque values of lead screws used in vehicle seat rails and the required torque values due to various disturbances that occur in actual systems. Lead screws were classified into square and trapezoidal threads and modeled by two lead type. Dynamic analysis models were constructed by applying contact conditions and rotational joints between the lead screw and nut. The validity of the dynamic model was verified by comparing the torque values obtained from rigid body dynamic analysis with the theoretically calculated torque values. Then, the lead screw was modeled as a flexible body to investigate the torque variation required for the lead screw when dynamic loads are considered. This study will help predict the actual torque values of lead screws for seat rails.

This research has been conducted to design upright parts of hand-made vehicles with the purpose of reducing material and machining cost while ensuring structural safety. Aluminum knuckles were modelled with three parts in order to enhance design flexibility as well as to reduce CNC machining cost. A vehicle model was constructed in CAD program and simulated in ADAMS View in order to estimate joint forces developing during 20 degree step steering condition at 60km/h. The joint forces obtained in the vehicle dynamics simulation were used for the structural analysis in ANSYS and dimensions of knuckle parts were adjusted until the lowest safety factor reached 2.0. The weight of knuckle decreased by 50% compared to the previous version that was designed without the structural analysis. The overall manufacturing cost decreased by 33% due to the reduction in the material as well as the CNC machining effort.