Parametric weight reduction design study of a small-diameter axial bearing for automotive tie rod applications

Sinan Dayı; Mehmet Çevik

doi:10.59400/mea3818

Parametric weight reduction design study of a small-diameter axial bearing for automotive tie rod applications

Sinan Dayı
Department of Mechanical Engineering, İzmir Katip Çelebi University, İzmir 35620, Türkiye
Mehmet Çevik
Department of Mechanical Engineering, İzmir Katip Çelebi University, İzmir 35620, Türkiye

Article ID: 3818

DOI: https://doi.org/10.59400/mea3818

Keywords: energy efficiency, parametric design, tempering, automotive applications, articulation torque

Abstract

Reducing component mass in automotive steering systems is a key strategy for achieving energy consumption reduction, cost efficiency, and sustainability, provided that functional safety and durability are preserved. This study experimentally investigates the feasibility of reducing the inner tie rod ball diameter from Ø29 mm to Ø26 mm while maintaining compliance with functional and durability requirements. Unlike predominantly simulation-driven studies, an industrial, hands-on experimental methodology is employed under realistic production conditions. A total of 192 inner tie rod assemblies were manufactured, comprising a Ø29 mm reference configuration and multiple Ø26 mm variants produced by systematically varying pressing force, tempering method, and tempering temperature. All assemblies were first subjected to functional screening based on articulation torque, axial travel, and minimum axial stiffness. Only configurations satisfying all acceptance criteria were advanced to wear and setting durability tests. Each assembly was evaluated using repeated measurements, and results are reported as mean values with corresponding standard deviations. The results show that articulation torque is the most sensitive parameter in reduced-diameter designs and is strongly influenced by tempering strategy and press force. Combining ball tempering with an increased press force provided stable functional behavior before and after both wear and setting tests, satisfying all acceptance criteria. The validated Ø26 mm configuration enables an estimated 10% weight reduction, approximately 8% material-related cost savings, and associated energy consumption reduction without introducing additional manufacturing steps. The findings deliver production-ready guidance for lightweight inner tie rod design while meeting stringent automotive safety standards.

Published

2025-10-02

How to Cite

Dayı, S., & Çevik, M. (2025). Parametric weight reduction design study of a small-diameter axial bearing for automotive tie rod applications. Mechanical Engineering Advances, 3(4). https://doi.org/10.59400/mea3818

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Issue

Vol. 3 No. 4 (2025)

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Article

This work is licensed under a Creative Commons Attribution 4.0 International License.

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This manuscript presents a sophisticated deep neural networks (DNNs)-driven adaptive control paradigm for concurrently regulating the attitude and suppressing structural oscillations of a flexible spacecraft in a fully three-dimensional domain. By leveraging Hamilton’s principle, the spacecraft’s motion is formulated as an infinite-dimensional dynamic model described by partial differential equations, capturing the subtle interactions between rigid-body rotational maneuvers and flexible panel deformations. In contrast to traditional schemes, the proposed control methodology integrates a DNNs module to compensate for uncertain actuator anomalies and external input disturbances in real time, thereby ensuring fault tolerance under arbitrary, potentially unbounded actuator malfunctions. A rigorously constructed Lyapunov-based stability analysis corroborates that the system’s energy, angular rates, and transverse deflections remain uniformly bounded and asymptotically converge to zero, even in the face of multiple actuator failures. This theoretical guarantee stems from the synergistic interplay between the network’s representational power and the adaptive control law’s robust learning capabilities. Extensive computational experiments demonstrate the efficacy of the developed framework in orchestrating high-precision attitude stabilization while simultaneously mitigating detrimental vibrations, showcasing the superior performance and resiliency of the proposed DNNs-infused control architecture.

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