DESIGN OPTIMIZATION AND STEADY- STATE ANALYSIS OF WHEEL RIM

International Journal of Mechanical and Production Engineering Research and Development (IJMPERD) ISSN (P): 2249–6890; ISSN (E): 2249–8001 Vol. 11, Issue 2, Apr 2021, 41-50 © TJPRC Pvt. Ltd.

DESIGN OPTIMIZATION AND STEADY- STATE ANALYSIS OF WHEEL RIM NARLAKANTI VIJAYBHASKAR1, Prof. Dr. Ing JENS SCHUSTER2 & SHAIK YOUSUF PASHA3 1

Product Refinement Master´s Student at Hochschule Kaiserslautern, Germany 2 3

Professor at Hochschule Kaiserslautern, Germany

Research Assistant at Hochschule Kaiserslautern, Germany

ABSTRACT FEM analysis is used to estimate the fatigue life and prediction of life cycle of automobile wheels by simulating using RFT. Basic simulation models under wheel rotating loading and air pressure condition have been carried out.

Automobile companies focus mainly on reducing weight of parts which reflects decrease in fuel cost. This can be achieved by replacing with new materials and optimising the production process. [1] In this project we have focused on reducing the strain and deformation of wheel by replacing Al alloy with other alloy materials and composites. This resulted in a new way of approach in optimising wheel rim. The modelling and simulation analysis is carried out using Solid works. [2] The analysis after optimisation shows that, the stresses and deformation generated are below the yield stress.

Received: Jan 20 2021; Accepted: Feb 10, 2021; Published: Feb 23, 2021; Paper Id.: IJMPERDAPR20215

INTRODUCTION The rim is defined as the outer circular design of the metal, on which inside edge of the tire is mounted on vehicles

Original Article

KEYWORDS: FEM, Thermal Analysis, Alloy wheels & Fatigue life

like automobiles.

Types of Rims 1. Wired spoke wheel 2. Steel disc shaped wheel 3. Light weight alloy wheel a. Al alloy wheel b. Mg alloy wheel c. Ti alloy wheel d. Composite wheel Various materials have different effects on strength, steady state, life cycle, durability of the wheels. Even when there is a change in the thickness by small amount, we can observe there is a drastic affect on the properties of the wheel rim. In this project, we have made analysis by giving supports and reducing thickness of wheel and applying different materials. [3]

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Narlakanti Vijaybhaskar, Prof. Dr. Ing Jens Schuster & Shaik Yousuf Pasha

Materials and their Characteristics Steel: This material has high fatigue strength. It has the ability to withstand highest cyclic loads. Just because of the weight factor the consumption of fuel is very high. [4] Al alloy: It has features like light weight, thermal conductive and physical properties like low heat, reusable. The main advantage is light weight, excellent precision, and various choices of design. [5] Mg alloy: It is 30 percent light weight than aluminium and can be admired for the stability in size and the resistance against impacts. [6] Ti alloy: It is famous because of the resistance towards corrosion and higher strength of about 2.5 times than aluminium. But there are disadvantages like processing, design, and cost factors. [7] PPS Composite: It different from the alloy wheels and its innovation was truly for the lightweight usage. But few consequences like low heat resistance against load. For this analysis, PPS is chosen as polymer matrix and reinforced with 30 percent glass fibres. [8] Design Considerations To categorise or identify a wheel for fitment purposes, there are four measurements.

Figure 1: Rim Design Parameters A.

Rim diameter

B.

Rim width

C.

Back spacing

D.

Bolts pattern

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Measuring Wheel Bolt Pattern,

Figure 2: Wheel Bolt pattern

Hub Centre Bore, The function of the hub rings is to withstand vibrations when the wheel is perfectly balanced.

Wheel offset, Offset is the distance from mounting surface to the true line of centre of the wheel rim.

Positive offset (+ve), mainly for front wheel drive (+45, 40, 35 offsets) Neutral offset, mainly for rear wheel drive (+20 offset) Zero - Negative offset (-ve), mainly for rear Wheel Drive (0 offset)

Figure 3: Types of Wheel Offsets

Just by changing the wheel thickness by few inches, it has a drastic affect on the properties of wheel rim.

Figure 4: Bolt Lug patterns www.tjprc.org

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Narlakanti Vijaybhaskar, Prof. Dr. Ing Jens Schuster & Shaik Yousuf Pasha

Bolt lug patterns can be four, five, six or eight lug holes. It is accurately measured using a bolt pattern gauge. For this model 5 lug pattern has been considered so that the strength and balancing of rim is not compromised.

Modelling of Rim Dassault Solidworks utilises a constant feature-based approach which was developed by PTC for model and assembly designs. Parasolid kernel is form in which the software system has been written. The parametric constraints confirm the form of the assembly or geometry. They are either numeric like line lengths or circle diameters, or geometric parameters, like tangent, parallel, concentric, horizontal or vertical. Or even numeric parameters related to one another, that permits them to capture model’s intention. It is however creator of the model part which needs to reply to changes and updates. The options like shape-based features of a 2nd or 3D sketch of model shapes like holes, boss-base, chamfer, split etc.

To build a model in Solidworks we start with a basic sketch. It may consist of parameters of design like points, conics, lines, arcs, and splines.

Relations like tangency, similarity, perpendicularity, and circularity are also used in modelling. It has a pure mathematics approach-based drafting with constraints, attributes and parameters. Sometimes even derivates of the function key is also used in drafting analysis. The size within the sketch may be controlled severally, or by relationships to alternative parameters within or outside of the sketch. In an assembly, the analog to sketch relations are mates even as sketch relations outline conditions like tangency, similarity, and circularity with reference to sketch geometry, assembly mates outline equivalent relations with reference to the individual components or elements, permitting the simple construction of assemblies. It also includes advanced pairing options like gear and cam follower mates, which allows modelled gear assemblies to reproduce the movement of a gear train. Finally, drafts may be created either from products or assemblies. Views are generated mechanically from the model, and notes, dimensions and tolerances will then be required for drafting.

Figure 5: Rim Design

Figure 6: Rim Draft Sheet

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Table 1: Rim Specifications No. Specifications Values 1. Width of rim 250 mm 2. Dia. of wheel 450 mm 3. Offset 25 mm 4. No of spokes 10 5. Thickness of rim 5 mm 6. Dia. of Bolt 20 mm 7. No of bolt holes 5

Analysis of Wheel Rim Mixture of structured and unstructured meshing are used to resolve differential equations in Solidworks auto mesh condition. The modelled undergoes meshing with the boundary conditions applied to the physical model. Wheel rim must be considered because it is in static condition and the boundary conditions like air pressures are applied. As from statics, load distribution due to air is seen completely on the wheel rim. [9] The following steps are required to perform the study in the subsequent manner, 

Design process study and its sorts. Conditions like model dimensions, properties, force or the other



Then define material properties and need not have to done if outlined within the CAD system.



For material definitions documented studies of fatigue and optimisation are used.



Restrains and masses are specified.



Drop check studies do not enable you to define outline restraints and derives apart from what's defined in

inputs.

the setup. 

It creates mechanically shelled mesh for surfaces and sheet metals of uniform thicknesses. And for sheet

metals we can also treat them as solid bodies. 

It mechanically meshes structure members with beams and creates mixed mesh when totally different

geometries exist in the model. 

Then define part contact and mesh model into small items such as components. Fatigue and optimisation

studies are used in documented studies of meshes. 

Next, run the study and examine the results.



And, we can outline material properties, loads, constraints, and control the mesh in any order of our

choice. We should make sure all mandatory inputs are to be defined before running the study.

Boundary Conditions and Loading 

Displacement

A. In x, y, z directions respectively Translation is zero.

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Narlakanti Vijaybhaskar, Prof. Dr. Ing Jens Schuster & Shaik Yousuf Pasha

B. In x, y, z directions respectively Rotation is zero.

Figure 7: Meshed Wheel Rim

The following conditions are applied on the five holes of the wheel rim. 

Loading Table 2: Loading Conditions 1. Inflation Pressure 0.241MPa 2. Lug bolt torque 115 Nm

The model is subjected to pressure of inflation i.e.0.241Mpa after constraining the model. And then the solution is done in the SOLVER module option of the analysis. Next, solution results such as stress, displacement is calculated for all the materials. [10]

Figure 8: Loads ACTING on Rim

After meshing and defining the loads onto the workpiece we need to run the study and then the results are calculated for three conditions, 

Rim under Stress Condition



Rim under Strain Condition



Rim under Displacement Condition

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This process is repeated for all the type of materials and the deformation scale is noted down. The material with the lowest Deformation scale is very much suitable for manufacturing the workpiece.

Material Properties In the automotive industry, alloy wheels are generally made of Al or Mg alloys. They consist of metal and different foreign mixtures. They help in improving properties over pure metals which are in general softer, ductile in nature. The Al or Mg alloys are light in weight but similar in properties like strength, heat conductivity and offer cosmetic look over steel wheels. Even though steel is used in wheel production, it is an alloy of iron and carbon. That is the reason we use alloy wheel only for wheels made of nonferrous alloy substances. [11] Table 3: Material Properties Young’s Modulus Poissons Ratio 2e+10MPa 0.3 7.1e+9MPa 0.33 4.5e+9MPa 0.35 9.6e+9MPa 0.36 3.3e+10MPa 0.43

Material Steel Aluminium Magnesium Titanium PPS

Density 7.85 g/cm^3 2.70 g/cm^3 1.80 g/cm^3 4.62g/cm^3 1.35 g/cm^3

Light weight wheels help in improved handling due to reduction in the mass permitting suspension to have a traction control and improved grip. Sometimes reduction in the total mass has also a negative effect due to the heating of brake pads when applying brakes. Generally, alloy wheels are casting made which are lighter, stronger and also expensive than forged wheel rims.

There are two types of solid wheels, one piece and standard. Standard solid wheels has two or three-piece style.

The multi-piece wheels includes inner rim base, outer rim lip and wheel centre piece with openings for lug bolts. Bolts have a control on the standard wheel.

RESULTS AND DISCUSSIONS The results are calculated for three conditions Rim under Stress Condition, Strain Condition and Displacement Condition 

Model Name - Titanium Rim

Study Name - Static Condition Plot Type

- Static Nodal Stress

Deformation Scale - 0.003

Figure 9: Titanium Rim under Stress Condition

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Narlakanti Vijaybhaskar, Prof. Dr. Ing Jens Schuster & Shaik Yousuf Pasha

Figure 10: Titanium Rim under Strain Condition

Figure 11: Titanium Rim under Displacement Condition 

Model Name -PPS composite Rim

Study Name - Static Condition Plot Type

- Static Nodal Stress

Deformation Scale - 0.005

Figure 12: PPS Rim under Stress Condition

Figure 13: PPS Rim under Strain Condition

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Figure 14: PPS Rim under Displacement Condition

CONCLUSIONS The modelling and analysis of five models are carried on same geometry in Solid works by changing the materials. The results are tabulated and then compared to analyse the similarities in different materials. This resulted for all the five models of rim, the deformation values are comparatively low for Titanium alloy next to steel which cannot be implemented now compared to all other alloys, which are used in analysis of this project. But when compared to cost of Titanium it is not affordable by automotive sector.

So, we are going for next better material whose values are nearer to Titanium and we got Composite material that is the best material next to titanium. So, the composite material can be used for the Rim manufacturing, which is the lighter and strength material compared to other remaining materials.

Table 4 : Results of Materials MODEL Deformation Scale

Steel Alloy

Aluminium Alloy

Magnesium Alloy

Titanium Alloy

0.001

0.064

0.040

0.003

PPS Composite 0.005

When compared to fluoro polymers, PPS show higher tensile strength, HDT, operating temperature, bonding, processing and toxic gas emission; but it lacks in terms of chemical resistance, cost, toughness and UV weathering. As compared to plastics, PPS has remarkable high thermal resistance, toughness and flashing. PPS has much higher temperature, fatigue performance, wear resistance and chemicals resistance.

Limitation of PPS: 

Low impact strength.



Processing at high temperatures.



Low thermal conductivity, due to the flexible sulfide linkage in between the aromatic rings. [12]

Because of these limitations, initially they can be implemented in manufacturing wheel rims which are utilised for light duty vehicles like golf carts, E-z-go cars. Meanwhile improvements in the thermal resistance properties are made and the situations like glowing brakes after a long ride downhill leading to partial melting and strength reduction can be eliminated.

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Table 5: Properties of PPS Material Property Density (kg/l) Tensile strength (MPa) Elongation at break (%) Flexural Modulus (MPa) Flexural Strength (MPa) HDT/A (1.8 Mpa) (°C) Izod notch Impact Strength (KJ/m2)

Unfilled

Glass Reinforced

1.35 65-85 6-8 3800 100-130 110 -

1.66 190 1.9 14000 290 270 11

Glass Mineral Filled 1.90 - 2.05 110-130 1.0-1.3 16k-19k 180-220 270 5-6

FUTURE SCOPE In the proposed work as we only considered just the pressure acting circumferentially on the wheel rim. This can be improved to analyse other forces that can act on the wheel rim and carry out structural analysis. Transient analysis and research must be done such that the composite material can withstand higher temperatures and does not get heated up due to which the material properties get affected.

REFERENCES 1.

"Finite element analysis of the classic bicycle wheel," in Raytheon Engineering and Production Support Indianapolis, Indiana, July 18, 2002.

2.

L. Wang, "The fatigue analysis of aluminium wheel rim," 2011.

3.

S. C. I. R. e. a. Alexandru Valentin Raduelescu, "Mechanical testing methods concerning the stress analysis for a vehicle wheel rim," in Mechanical Testing and Diagnosis, 2012.

4.

H. N. Sunil N Yadav, "Modelling and analysis of camber angle on fatigue life of wheel rim of passenger car by using radial fatigue testing.," International Journal of Engineering Science and Innovative Technology (IJESIT), 2013.

5.

N. S. B. N. Meghashyam P, "Design and analysis of wheel rim using CATIA & ANSYS.," International journal of application or innovation in engineering management, 2013.

6.

S. C. Satyanarayana N, “Fatigue analysis of aluminium alloy wheel under radial load," International Journal of Mechanical and Industrial Engineering (IJMIE) ISSN No. 2231–6477, 2012.

7.

M. S. P. J. Trapti Sharma, "Failure analysis of wheel rim," International Journal of Automobile Engineering Research & Development (IJAERD) ISSN 2277-4785, 2013.

8.

S. Das, "Design and weight optimization of aluminium alloy wheel," International Journal of Science and Research Publications ISSN 2250-3153, 2014.

9.

S. T. Lam PC, "An analysis of stress and displacement distribution in a rotating rim subjected to pressure and radial loads," International Journal of Research in Mechanical Engineering, 2014.

10. S. M. Suwarnatorgal, "Stress analysis of wheel rim," International Journal of Mechanical Engineering and Research ISSN. 11. M. Ashby, "Material property data for engineering materials," Cambridge University, January, 2016.

12. https://omnexus.specialchem.com/selection-guide/polyetheretherketone-peek-thermoplastic.

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