Ijri me 01 008

International Journal of Research and Innovation (IJRI)

International Journal of Research and Innovation (IJRI) 1401-1402

GEOMETRICAL OPTIMIZATION AND EVALUATION OF ALLOY WHEEL FOUR WHEELER

P.Praveen 1, D.Gopichand2, 1 Research Scholar, Department Of Mechanical Engineering, Mother Theresa Institute of Technology(mist) Khammam,India.

2 Assistant professor , Department Of Mechanical Engineering, Mother Theresa Institute of Technology(mist) Khammam,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.

The goal of the project is to suggest optimum geometric shape and material for alloy wheel of a four wheeler.

In the first step previous journals will be studied to understand actual problem, selection of materials, selection of shape’s and rectification method.

In the next step parametric models will be prepared for further analysis purpose Evaluation will be done on the model using Ansys work bench for reading results.

Different geometric shapes of cross members will be implemented according to the stress location observed from evaluation process.

Analysis/evaluation will be carried out on different models to find best shape of cross member.

On the optimum model analysis will be carried out using different material to ensure quality.

Result tables and conclusion will be made according to the results obtained from Ansys

Keywords: - Geometric, Alloy wheel, Optimization, Evaluations. *Corresponding Author: P.Praveen , Research Scholar, Department Of Mechanical Engineering, Mother Theresa Institute of Technology(mist) Khammam,India.

Published: Sep 22, 2014 Review Type: peer reviewed Volume: I, Issue : III

Citation: P.Praveen, Research Scholar (2014) GEOMETRICAL OPTIMIZATION AND EVALUATION OF ALLOY WHEEL FOUR WHEELER

Problem Description Previously steel wheels are used to manufacture wheels for the higher strength, but these alloy wheels are heavily due to its density and also giving trouble to manufacture because of its higher melting point and hard to do casting it. Weight is also playing crucial role in mileage. After that aluminum and magnesium took the place for the manufacturing of alloy wheel, but these alloy wheels are not giving good life due to its low compressive and yield strength.

As above these aluminum and magnesium wheels getting yield (bends) at the larger run and also these types of materials are not permitting heavy loads.

Methedology As observed above problem and literature survey new type of alloy wheels are not permitting heavy loads and also getting yield (bend) during bumps and pits in long run.

Hence in this project geometric optimization and material optimization used to solve the above said problems.

New type of composite Zamak is implemented in this thesis NTRODUCTION 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

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International Journal of Research and Innovation (IJRI)

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.

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 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

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.

Most alloy wheels are manufactured using casting, but some are forged. Forged wheels are usually lighter, stronger, but much more expensive than cast wheels.

INTRODUCTION TO CAD Computer-aided design (CAD), also known as computer-aided design and drafting (CADD), is the use of computer technology for the process of design and design-documentation. Computer Aided Drafting describes the process of drafting with a computer. CADD software, or environments, provide the user with input-tools for the purpose of streamlining design processes; drafting, documentation, and manufacturing processes. CADD output is often in the form of electronic files for print or machining operations. The development of CADD-based software is in direct correlation with the processes it seeks to economize; industry-based software (construction, manufacturing, etc.) typically uses vector-based (linear) environments whereas graphic-based software utilizes raster-based (pixelated) environments.

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.

INTRODUCTION TO CREO 2.0 (Pro/Engineer)

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

Customer requirements may change and time pressures may continue to mount, but your product design needs remain the same - regardless of your project's scope, you need the powerful, easy-to-use, affordable solution that Creo 2.0 (Pro/Engineer) provides.

Creo 2.0 (Pro/Engineer) Wildfire is the standard in 3D product design, featuring industry-leading productivity tools that promote best practices in design while ensuring compliance with your industry and company standards. Integrated Creo 2.0 (Pro/Engineer) CAD/CAM/CAE solutions allow you to design faster than ever, while maximizing innovation and quality to ultimately create exceptional products.

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International Journal of Research and Innovation (IJRI)

Model Of Alloy Wheel Stright Cross Member

The above image shows sketcher

Model Of Alloy Wheel H-Type Cross Member

The above image shows h-type cross member

Material properties and boundary conditions Load calculations:

The above image shows final model Model Of Alloy Wheel Inclined Cross Member

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 =186 = 0.186 N/mm2 For dynamic conditions and road conditions = Dynamic factor 5.2*.186=0.967Mpa Therefore we are considering 1Mpa Constrained at centre hub bolt system MATERIAL PROPERTIES Aluminum Yield strength: 3.49e+008 N/m2 Tensile strength: 3.59e+008 N/m2 Mass density: 2800 kg/m3 Elastic modulus: 7.1e+010 N/m2 Poisson's ratio: 0.33 Thermal expansion coefficient: 3.5e-005 /Kelvin

The above image shows inclined cross member Model Of Alloy Wheel Y-Type Cross Member

Magnesium Alloy Yield strength: 1.05e+008 N/m2 Mass density: 1700 kg/m3 Elastic modulus: 4.5e+010 N/m2 Poisson's ratio: 0.35 Thermal expansion coefficient:2.5e-005 /Kelvin zamak Model type: Linear Elastic Isotropic Default failure criterion: Max von MisesStress Yield strength: 2.68e+008 N/m2 Tensile strength: 3e+007 N/m2 Mass density: 6040 kg/m3 Elastic modulus: 8.3e+010 N/m2 Poisson's ratio: 0.3

The above image shows y-type cross member

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International Journal of Research and Innovation (IJRI)

Structural Analysis

The above image is the imported model of straight cross member.

The above image shows von-misses stress Fatigue Analysis

The above image showing the meshed modal.

Results

The above image shows safety factor Buckle Analysis

The above image shows displacement

The above image shows buckle factor

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International Journal of Research and Innovation (IJRI)

Conclusion This paper presents optimized alloy wheel for car by simulating alloy wheel on different geometric shapes with different materials.

Modeling of alloy wheel was done using creo 2.0 and simulation works was done in ansys Simulation is a done on alloy wheel with Straight, inclined and Y-shaped cross members and Hshaped cross members to find the structural characteristics.

Simulation is a done using, aluminum A360, and Magnesium and ZAMAK materials.

The above image shows safety factor Straight cross member STRUCTURAL ANALYSIS Total deformation

aluminum

magnesium

Zamak

0.033729

0.054397

1.175e-8

Stress

22.978

22.887

23.278

Strain

0.00032666

0.00051377

1.1731e-10

FATIGUE ANALYSIS Factor of safety

1.518844

4.58775724

11.5

Biaxiality indication

0.99176

0.098749

0.99251

Alternating stress

22.978

22.887

23.278

BUCKLE ANALYSIS Total deformation

1.064

1.0816

1.0628

Bulking load factor

36.846

23.406

1.0316e+8

H -Types Cross Member

While comparing geometric shape Y-shaped cross member’s model is showing good results than other models.

As per the above results ZAMAK material along with Y-shaped cross members 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 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

STRUCTURAL ANALYSIS Total deformation

As per the factor of safety ZAMAK is giving maximum factor of safety with in low cost the minimum FOS value for wheel parts should be 3 or more.

aluminum

magnesium

Zamak

0.033605

0.053512

1.1716e-8

Stress

25.094

24.989

25.302

Strain

0.0003573

0.00056185

1.277e-10

FATIGUE ANALYSIS Factor of safety

1.390770702

4.20184881

10.592

Biaxiality indication

0.98137

0.98786

0.98493

Alternating stress

25.094

24.989

25.302

BUCKLE ANALYSIS Total deformation

1.0569

1.0573

1.0563

Bulking load factor

37.103

23.603

1.0389e+8

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International Journal of Research and Innovation (IJRI)

[6] Numerical simulation of dynamic side impact test for an aluminium alloy wheel Scientific Research and Essays Vol. 5(18), pp. 2694-2701, 18 September, 2010 Available online at http://www.academicjournals.org/SRE ISSN 1992-2248 Š2010 Academic Journals [7] Evaluation of fatigue life of aluminum alloy wheels under radial loads P. Ramamurty Raju a,*, B. Satyanarayana b, K. Ramji b, K. Suresh Babu a Received 12 November 2006; accepted 19 November 2006 Available online 17 January 2007 2006 Elsevier Ltd. All rights reserved.

[8] Fatigue life prediction of a heavy vehicle steel wheel under radial loads by using finite element analysis journal homepage: www.elsevier.com/locate/engfailanalArticle history: Received 7 March 2011 Received in revised form 10 October 2011 Accepted 18 October 2011 Available online 25 October 2011 [9] Fatigue strength improvement by ultrasonic impact treatment of highly stressed spokes of cast aluminium wheels Berg-Pollack a, F.-J. Voellmecke b, C.M. Sonsino a,Elsevier Ltd. All rights reserved journal homepage: www.elsevier.com/locate/ijfatigueArticle history: Received 28 June 2010 Accepted 28 September 2010 Available online 13 October 2010 [10] Finite element simulation of wheel impact test VOLUME 28 ISSUE 2 June 2008 C.L. Chang*, S.H. Yang Mechanical Engineering Department, National Yunlin University of Scienceand Technology, Yunlin, 640, Taiwan, R.O.C. [11] Understanding the Influence of Pressure and Radial Loads on Stress and Displacement Response of a Rotating Body: The AutomobileWheelJ. Stearns, T. S. Srivatsan, X. Gao, and P. C. Lam Department of Mechanical Engineering, The University of Akron, Akron, OH 44325-3903, USA Hindawi Publishing Corporation International Journal of Rotating Machinery Volume 2006, Article ID 60193, Pages 1–8 DOI 10.1155/IJRM/2006/60193 [12] Magnesium alloys for structural applications; recent advances JOURNAL DE PHYSIQUE IV Colloque C7, suppl6ment au Journal de Physique 111, Volume 3, novembre 1993H. WESTENGEN Norsk Hydro Research Centre, 3901 Porsgrunn, Norway

durability approval of wheel hubs. Society of Automotive Engineer, Inc. Warrendale, Pennsylvania.

[18]Hsu, Y.-L., Wang, S.-G., Liu, T.-C. (2004). Prediction of fatigue failure of aluminum disc wheel using the failure probability contour based on historical test data. [19] Journal of the Chinese Institute of Industrial Engineers, vol. 21, no. 6, p. 551-558.

[20]Kocabicak, U., Firat, M. (2001). Numerical analysis of wheel cornering fatigue tests, Engineering Failure Analysis, vol. 8, p. 339- 354.

Author

P.Praveen , Research Scholar, Department Of Mechanical Engineering, Mother Theresa Institute of Technology(mist) Khammam,India.

D.Gopichand, Assistant professor , Department Of Mechanical Engineering, Mother Theresa Institute of Technology(mist) Khammam,India.

[13] New extrusion process of Mg alloy automobile wheels WANG QiangZHANG Zhi-min 2010 [14] Simulation of wheel impact test using finite element method Chia-Lung Chang *, Shao-Huei Yang Department of Mechanical Engineering, National Yunlin University of Science and Technology, Douliu, Yunlin 640, Taiwan, ROC journal homepage: www.elsevier.com/ locate/engfailanalArticle history: Received 26 December 2008 Accepted 29 December 2008 Available online 11 January 2009 [15] simulation test of automotive alloy wheel using computer aided engineering software mohd izzat faliqfarhan bin baharom universiti malaysiapahang [16] Guo, M., Bhandarkar, R., Lin, B. (2004). Clamp load consideration in fatigue life prediction of a cast aluminum wheel using finite element analysis. Society of Automotive Engineer, Inc. Warrendale, Pennsylvania.

[17]Grubisic, V., Fischer, G. (1998). Design criteria and 48