International Journal of Research and Innovation (IJRI)
International Journal of Research and Innovation (IJRI) 1401-1402
GEOMETRICAL AND MATERIAL OPTIMIZATION OF ALLOY WHEEL FOR FOUR WHEELER
B. Anusha Srikanta1, P.veeraraju2, 1 Research Scholar, Department Of Mechanical Engineering,G I E T, Rajahmundry, AP, India. 2 Professor , Department Of Mechanical Engineering, G I E T, Rajahmundry, AP, India.
Abstract Alloy wheels are automobile wheels which are made from an alloy of aluminum or magnesium metals or sometimes a mixture of both. Alloy wheels differ from normal steel wheels because of their lighter weight, which improves the steering and the speed of the car. Alloy wheels will reduce the unstrung weight of a vehicle compared to one fitted with standard steel wheels. The benefit of reduced unstrung weight is more precise steering as well as a nominal reduction in fuel consumption. At present four wheeler wheels are made of aluminum alloys or steel. In this aluminum alloy wheel will be replaced with different alloys like zamak and magnesium. In this a parametric model will be made to design for alloy wheel used in four wheeler by collecting data from reverse engineering process from existing model. Design has to be evaluated by analyzing the model by considering the constraints as ultimate stresses and variables as different materials and different loads. The main aim of the project is to suggest best geometric shape along with material, for geometrical optimization four different shapes of straight, inclined, y-shape, and honey comb-shape are analyzed with above described materials by applying two loads. Structural analysis will be done at maximum load conditions to determine structural characteristics. Buckle analysis will be done to determine the buckle factors for all above models and materials. *Corresponding Author:
Steel Wheel
B. Anusha Srikanta , Research Scholar, Department Of Mechanical Engineering, G I E T, Rajahmundry, AP, India.
The first type of wheel worth mentioning, and by far the most-used wheel, is the steel wheel. This kind of wheel consists of several sheets of steel, stamped into shape and typically welded together. This type of wheel is strong, but heavy. They are found on every kind of vehicle from sports cars to the larger pickup trucks; the wheels look different but are essentially the same device.
Published: January 23, 2014 Review Type: peer reviewed Volume: I, Issue : I
Citation: B. Anusha Srikanta, Research Scholar (2014) GEOMETRICAL AND MATERIAL OPTIMIZATION OF ALLOY WHEEL FOR FOUR WHEELER
INTRODUCTION TO WHEELS Wheels A wheel is a circular device that is capable of rotating on its axis, facilitating movement or transportation while supporting a load (mass), or performing labour in machines. Common examples are found in transport applications. A wheel, together with an axle overcomes friction by facilitating motion by rolling. In order for wheels to rotate, a moment needs to be applied to the wheel about its axis, either by way of gravity, or by application of another external force. More generally the term is also used for other circular objects that rotate or turn, such as a ship's wheel, steering wheel and flywheel. Types Of Wheels There are only a few types of wheels still in use in the automotive industry today. They vary significantly in size, shape, and materials used, but all follow the same basic principles.
Rally Wheel The second type of wheel to be mentioned is the rally wheel. These are essentially steel wheels but they are made somewhat differently, and tend to consist of a heavier gauge of steel. While the inner portion of a steel wheel is generally welded to the rim along its entire circumference, a steel wheel's inner portion is cut to resemble the spokes of a mag wheel, and is welded accordingly. Mag Wheel Mag wheels are cast and/or milled wheels typically made from aluminum or an alloy thereof. They used to be made of magnesium for their light weight and strength, but magnesium catches fire somewhat easily and is very difficult to put out. This is unfortunate, because it is superior to aluminum in every other way. This tendency also makes it a dangerous metal to work with, because piles of shavings tend to burst into flame and burn through concrete surfaces when they get too hot.
1
International Journal of Research and Innovation (IJRI)
Spoke Wheel As previously mentioned, spoke wheels (sometimes with more than 100 spokes) are still in use today and are popular on roadsters and low-riders. They tend to be fairly low in weight, and are reasonably strong. They have an "old school" appearance and style which is often highly sought after.
lighter than the equivalent size steel wheel. Reduction in overall vehicle mass can also help to reduce fuel consumption. Better heat conduction can help dissipate heat from the brakes, which improves braking performance in more demanding driving conditions and reduces the chance of brake failure due to overheating. Aluminium Alloy Wheel
Centerline Wheel Various combinations of these technologies can be used to produce other, more unusual wheels. Large earth-moving vehicles such as the more gargantuan dump trucks often have some degree of the vehicle's suspension actually built into the wheel itself, lying between the hub and rim in place of spokes. Also, various companies make wheels which are designed like steel wheels but are made of aluminum -- The most famous of these are made by centerline, and the style is actually called the centerline wheel. Mounting Wheels are mounted to the hub by a combination of lug bolts, or studs, and lug nuts. The studs are mounted to the hub, which is attached to a hub carrier or suspension upright. The wheel has holes to match these studs, and is placed over them. The lug nuts are then applied and tightened to the proper tension. Hub- And Lug-Centricism Automobile wheels are considered to be either hubcentric or lug-centric, the difference being how the wheel is centered. If a wheel is off-center, the result is a lack of balance and a tendency for that wheel to bounce as the radius changes. Hub-centric wheels are centered by the center bore of the wheel matching the protruding portion of the hub, and lug-centric wheels are centered simply by the position and diameter of the lug bolts. Adapter rings are available for some wheels to center them to the hub, though it is generally not necessary. Some lugcentric wheels are centered by a beveled edge on the lug nuts matching a bevel on the wheel's holes. Introduction To Alloy Wheel Alloy wheels are automobile (car, motorcycle and truck) wheels which are made from an alloy of aluminium or magnesium metals (or sometimes a mixture of both). Alloy wheels differ from steel wheels in a number of ways: •Typically lighter weight for the same strength •Better conductors of heat •Improved cosmetic appearance Lighter wheels can improve handling by reducing unsprung mass, allowing suspension to follow the terrain more closely and thus provide more grip, however it's not always true that alloy wheels are
Alloy Wheels Are Not Only For Improved Driving Performance, They Are Also For Cosmetic Purposes. The Alloys Used Are Largely Corrosion-Resistant, Permitting An Attractive Bare-Metal Finish, With No Need For Paint Or Wheel Covers, And The Manufacturing Processes Allow Intricate, Bold Designs. In Contrast, Steel Wheels Are Usually Pressed From Sheet Metal, And Then Welded Together (Often Leaving Unsightly Bumps) And Must Be Painted (As They Corrode Otherwise) And/Or Hidden With Wheel Covers / Hub Caps. Alloy Wheels Are Prone To Galvanic Corrosion If Appropriate Preventative Measures Are Not Taken, Which Can In Turn Cause The Tires To Leak Air. Also, Alloy Wheels Are More Difficult To Repair Than Steel Wheels When Bent, But Their Higher Price Usually Makes Repairs Cheaper Than Replacement And Even Severely Damaged Wheels Can Often Be Repaired To Like New, Though This Depends On How Badly The Owner Wishes To Salvage The Wheel And Its Intrinsic Worth Or Availability. Alloy Wheels Are More Expensive To Produce Than Standard Steel Wheels, And Thus Are Often Not Included As Standard Equipment, Instead Being Marketed As Optional Add-Ons Or As Part Of A More Expensive Trim Package. However, Alloy Wheels Have Become Considerably More Common Since 2000, Now Being Offered On Economy And Subcompact Cars, Compared To A Decade Earlier Where Alloy Wheels Were Often Not Factory Options On Inexpensive Vehicles. Alloy Wheels Have Long Been Included As Standard Equipment On Higher-Priced Luxury Or Sports Cars, With Larger-Sized Or "Exclusive" Alloy Wheels Being Options. The High Cost Of Alloy Wheels Makes Them Attractive To Thieves; To Counter This, Automakers And Dealers Often Use Locking Wheel Nuts Which Require A Special Key To Remove. 2
International Journal of Research and Innovation (IJRI)
Most Alloy Wheels Are Manufactured Using Casting, But Some Are Forged. Forged Wheels Are Usually Lighter, Stronger, But Much More Expensive Than Cast Wheels. Aftermarket Wheels A Sizeable Selection Of Alloy Wheels Are Available To Automobile Owners Who Want Lighter, Prettier, Rarer, And/Or Larger Wheels On Their Cars, In Order To Increase Performance, Manipulate Handling And Suspension, And/Or Signify Luxury, Sportiness, Or Wealth. These Wheels Have Become A Part Of Pop Culture. Section Views Of Alloy Wheel
3D model for straight cross member
3D model for inclined cross member
3D model for Y-shape cross member
3D model for honey comp-shape cross member
3
International Journal of Research and Innovation (IJRI)
Introduction: COSMOS Works is a design analysis automation application fully integrated with Solid Works. This software uses the Finite Element Method (FEM) to simulate the working conditions of your designs and predict their behavior. FEM requires the solution of large systems of equations. Powered by fast solvers, COSMOS Works makes it possible for designers to quickly check the integrity of their designs and search for the optimum solution. COSMOS Works comes in several bundles to satisfy your analysis needs. It shortens time to market by testing your designs on the computer instead of expensive and time- consuming field tests. COSMOS Works uses the Finite Element Method (FEM). FEM is a numerical technique for analyzing engineering designs. FEM is accepted as the standard analysis method due to its generality and suitability for computer implementation. FEM divides the model into many small pieces of simple shapes called elements effectively replacing a complex problem by many simple problems that need to be solved simultaneously. Elements share common points called nodes. The process of dividing the model into small pieces is called meshing. The behavior of each element is well-known under all possible support and load scenarios. The finite element method uses elements with different shapes. The response at any point in an element is interpolated from the response at the element nodes. Each node is fully described by a number of parameters depending on the analysis type and element used. For example, the temperature of a node fully describes its response in thermal analysis. For structural analyses using shells, the response of a node is described by three translations and three rotations. For structural analyses using tetrahedral elements, the response of a node is described by three translations. These are called degrees of freedom (DOFs). Analysis using FEM is called Finite Element Analysis (FEA).
Structural Analysis Of Straight Cross Member Type Wheel
The above images shows the model of the alloy wheel with straight cross member type
The above image shows the loads applied
The above image is showing meshed component
Material: ALLUMINIUM
Load calculations: Type of vehicle: Mercedes benz c250 1.8let,201 HP, torque 1.5789mpa at 2000rpm Car weight – (wc) = 1944 kg’s 5 passengers + luggage - (wp) = 500 kg’s Area (A) = 128738.66 mm2
the above image is showing von-misses stress
4
International Journal of Research and Innovation (IJRI)
Structural Analysis Of Inclined Cross Member Type Wheel
The above images shows the model of the alloy wheel with straight cross member
The above image is showing meshed component
Material: STEEL
The above image is showing von-misses stress
The above image is showing displacement
Structural Analysis Of Y-Shape Cross Member
The above images shows the model of the alloy wheel with y-shape cross member
The above image is showing meshed component
Material: MAGNESIUM
The above image is showing von-misses stress
The above image is showing displacement
5
International Journal of Research and Innovation (IJRI)
Structural Analysis Of Honey Comb -Shape Cross Member
CONCLUSION The above image is showing von-misses stress
The above image is showing displacement
Cast alloy steel Model
Stress
Displacement
Strain
Straight
15.0051
0.0103362
0.00005987
Inclined
25.5087
0.0104004
0.00007740
Y - shape
17.5281
0.00897626
0.00005191
Honeycomb
5.88082
0.00896603
0.00001046
Magnesium Model
Stress
Displacement
Strain
Straight
16.618
0.043015
0.000268224
Inclined
24.4902
0.0436577
0.000317877
Y - shape
17.0535
0.0376351
0.000226803
Honeycomb
5.00034
0.0377355
0.00004338
As per the buckle analysis also ZAMAK is the right choice due to low deflections in buckle consideration. Advantage of using ZAMAK: we can manufacture ZAMAK alloy wheels using metal injection molding machines so that we can increase production rate and also we can reduce cost of production while comparing with steel and magnesium wheels. REFERENCES 1.H. WESTENGEN. 2.J. T. de Assis, H. Alves, I. Lima, V. Monin, M. dos Anjos, R. T. Lopes.
Zamak Model
Stress
Displacement
Strain
Straight
15.5894
0.0235479
0.000139443
Inclined
24.8723
0.0237676
0.000175194
Y - shape
17.2278
0.0204995
0.000120639
Honeycomb
5.50315
0.0204909
0.0000237
Stress Graph
In this paper we are presenting optimized alloy wheel for car by simulating alloy wheel on different geometric shapes with different materials. Modeling of alloy wheel was done using solid works and simulation works was done in simulation works. We have done simulation on alloy wheel with Straight, Slant and Y-shaped cross members and honey-comb structure. We have done simulation using steel, aluminum A360, and Magnesium and ZAMAK materials. As per the above results ZAMAK material along with honey-comb structures better. While comparing with other materials ZAMAK is having some higher stress and displacement but the values had negligible difference. ZAMAK is the right choice due to its higher tensile and yield strength
3.Amalia Ana DASCĂL, 2.Daniel CĂRĂULEANU. 4.J. Stearns, T. S. Srivatsan, X. Gao, and P. C. Lam. 5.WANG Qiang, ZHANG Zhi-min, ZHANG Xing, LI Guo-jun. 6.STRENGTH OF MATERIAL BY RAMAMRUTHAM. 7.DMM BY RS KURMI. 8.AUTOMODILE ENGINEERING BY RS KURMI
6
International Journal of Research and Innovation (IJRI)
AUTHORS:
B. Anusha Srikanta1, Research Scholar, Department Of Mechanical Engineering,G I E T, Rajahmundry, AP, India.
P.veeraraju2, Professor , Department Of Mechanical Engineering, G I E T, Rajahmundry, AP, India.
7