Simulation of biaxial wheel test and fatigue life estimation considering the influence of tire and wheel camber

The vehicle may be towed without the engine but it is not possible without the wheels. Road wheel is a significant structural member of the vehicular suspension system that supports the static and dynamic loads encountered during vehicle operation. As in the case of an automobile wheel maximum load is applied on the alloy wheel. Proper analysis of the alloy wheel plays a significant role for the safety of the passenger cars. Alloy wheels which are intended for normal use on passenger cars, undergo three tests and have to pass before going into the production: Dynamic Cornering Fatigue Test, Dynamic Radial Fatigue Test and Impact Test. Most of aluminium alloy wheels manufacturing companies have done several testing of their product however information of their method on simulation test is often kept limited. During a part of research a static and fatigue analysis of aluminum alloy wheel A356.0 was carried out using FEA package. The 3-D model was imported from CATIA into ANSYS using the appropriate format. Finite element analysis (FEA) is carried out by simulating the test conditions to analyze stress distribution and fatigue life of the aluminium alloy wheel rim of passenger car. Experimental analyses are carried out by radial fatigue testing machine for evaluation of fatigue life under influence of camber angle. The test indicates that integrating FEA and nominal stress method is a good and efficient method to predict alloy wheels fatigue life. In this paper by observing the results of both static and dynamic analysis the aluminium alloy is suggested as better material.

Analysis of Static Stress in an Alloy Wheel of the Passengercar

A finite element based method is used to simulate the radial test of an automobile wheel. Besides the certainty of results obtain through practical, computer aided simulation of the wheel, using ANSYS replicates the actual experiments. The fatigue life limit factors introduced by other researchers were used to obtain the stress and fatigue reduction factors which were further used to estimate the S-N curve as the stress-Life method is employed in predicting the fatigue life of a rim.During the static analysis of the steel wheel, it was discovered that the maximum stress concentration ( ) occurred at the spokes and ventilation hole of the rim under loads, Fr and pi. It was observed that when the wheel rotates at a speed of 1790 rpm under the stated loads, the fatigue crack propagates at the point of maximum stress concentration.

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Computer Aided Design and Simulation of Radial Fatigue Test of Automobile Rim Using ANSYS

Visual inspection of finished products has always been one of the basic and most recognized applications of quality control in any industry. This inspection remains largely a manual process conducted by operators, and thus faces considerable limitations that make it unreliable. Therefore, it is necessary to automatize this inspection for better efficiency. The main goal of this thesis is to design an automatic visual inspection system for surface inspection and monitoring. The specific application of wheel inspection is considered to study the design and installation setup of the imaging system. Then, two inspection methods are developed: a defect detection method on the product’s surface and a change-point detection method in the parameters of the non-stationary inspection process. Because in an industrial context it is necessary to control the false alarm rate, the two proposed methods are cast into the framework of hypothesis testing theory. A parametric approach is proposed to model the non-anomalous part of the observations. The model parameters are estimated to design a statistical test whose performances are analytically known. Finally, the impact of illumination degradation on the defect detection performance is studied in order to predict the maintenance needs of the imaging system. Numerical results on a large set of real images highlight the relevance of the proposed approach

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Automatic Vision System for Surface Inspection and Monitoring : Application to Wheel Inspection

Bu çalışmada A356 alaşımından üretilen binek araç jantlarının mekanik yükleme altında tasarım ve ağırlık optimizasyonu gerçekleştirilmiştir. Bu kapsamda seçilen bir jant modeli üzerinde geleneksel tasarım uygulamalarında mühendislik tecrübeleri ile gerçekleştirilen tasarım aşamalarında belirlenen ölçüler tasarım parametreleri olarak seçilmiştir. Tasarımda ANSYS Workbench’de “Sayısal Deney Tasarımı” yöntemi ile tasarım noktaları belirlenmiştir. “Cevap Yüzeyi Metodu” kullanılarak en iyi tasarım elde edilmiştir. Sonuç olarak jant ağırlığı ve deformasyonuna en çok etki eden parametreler belirlenmiş, tasarımın mekanik davranışı iyileştirilmiş ve daha hafif bir jant elde edilmiştir. Jantın geometrisi üzerinde gerçekleştirilen iyileştirme ile yorulma davranışı da iyileştirilmiştir. In this study, design and weight optimization of passenger car wheels made of A356 alloy was conducted. In the course of the study a wheel was chosen and its dimensions that are generally used in the traditional design applications which applied by engineering experience were determined as design parameters. Design of Computational Experiments was used in ANSYS Workbench and optimum design was determined by Response Surface Method. As a result the most effective parameters on wheel weight and deformation were determined, the mechanical behavior of the wheel was improved and a lighter wheel was obtained. By improvements on wheel geometry, fatigue behavior was improved.

Design and weight optimization of aluminum alloy wheels

To improve the quality of aluminum wheels, a new method for evaluating the fatigue life of aluminum wheels is proposed in this paper. The ABAQUS software was used to build the static load finite element model of aluminum wheels for simulating the rotary fatigue test. The equivalent stress amplitude was calculated based on the nominal stress method by considering the effects of mean load, size, fatigue notch, surface finish and scatter factors. The fatigue life of aluminum wheels was predicted by using the equivalent stress amplitude and aluminum alloy wheel S-N curve. The results from the aluminum wheel rotary fatigue bench test showed that the baseline wheel failed the test and its crack initiation was around the hub bolt hole area that agreed with the simulation. Using the method proposed in this paper, the wheel life cycle was improved to over 1.0×105 and satisfied the design requirement. The results indicated that the proposed method of integrating finite element analysis and nominal stress method was a good and efficient method to predict the fatigue life of aluminum wheels.

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Liangmo Wang

Papers

Fatigue Life Analysis of Aluminum Wheels by Simulation of Rotary Fatigue Test