Improvement in the Wheel Design Using Realistic Loading Conditions - FEA and Experimental Stress Comparison
06 Oct 2011-
About: The article was published on 2011-10-06. It has received 10 citations till now. The article focuses on the topics: Stress (mechanics).
Citations
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TL;DR: In this paper, the design development of a CFRP wheel for a high-performance roadster was presented, where the wheel was instrumented with strain gauges and a bending moment was applied to the hub using a custom-built test rig.
Abstract: Abstract The wheel of a passenger vehicle must be designed to be safe and light. Despite the tremendous potential of carbon fibre as an automotive material due to high strength and low weight, the prevalence of carbon fibre reinforced plastics (CFRPs) in vehicle wheels is limited. Manufacturing and testing CFRP prototypes is expensive. Thus it is advantageous to develop simulation models for composite weight reduction. The simulation models can provide insight into how lighter CFRP wheels can be designed. This study presents the design development of a CFRP wheel for a high-performance roadster; the CFRP wheel is offered by an automotive manufacturer as a high-performance option instead of aluminium wheels. Finite element (FE) simulations were initially conducted assuming an isotropic material. This initial model was used to eliminate stress concentrations and to design and manufacture an initial CFRP wheel. The CFRP wheel weight is 6.8 kg as compared to the original aluminium wheel which weighs 8.1 kg. This initial design passed the dynamic cornering fatigue test (the most stringent strength test for wheels). Thereafter the wheel was instrumented with strain gauges and a bending moment was applied to the hub using a custom-built test rig. The test rig produced a static load equivalent to the dynamic cornering fatigue test (in which the applied bending moment varies sinusoidally). The test rig allowed for the deflection of the load arm to be measured. The comparison of the experimentally measured strains and an FE model which includes the CFRP laminate properties showed good agreement. Two alternative laminate options were simulated using the FE model. These showed both an increase in stiffness and a calculated weight reduction. This study shows that an aluminium wheel for a high-performance roadster can be redesigned using CFRP to be 16% lighter and using a FE model a further 152 g weight reduction is possible (18% weight reduction in total when compared to the aluminium wheel).
13 citations
TL;DR: In this paper, a conventional AGV designed previously by an AGV manufacturer to bring a payload of 70 kg is analyzed using the Finite Element Method (FEM) and SolidWorks software is used to do the FEA simulation.
Abstract: Automated Guided Vehicle is a mobile robot used in various industries to transfer goods and materials from one place to another in the industrial compound such as production line and warehouses. Due to the payload it should carry, the design should be able to handle certain level of mechanical stress. The optimization study is important to assure the material and design is safe an optimum under the specified conditions before the AGV is manufactured. In this study, a conventional AGV designed previously by an AGV manufacturer to bring a payload of 70 kg is analyzed using the Finite Element Method (FEM) and SolidWorks software is used to do the FEA simulation. This paper also explain on how the factor of safety for the AGV is derived. The parameter change in this study were the thickness of the sheet metal used to build the AGV while the study output is the stress level, factor of safety and weight of the AGV.
5 citations
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10 Jan 2017
4 citations
TL;DR: In this article, a finite element analysis (FEA) model is developed to obtain the normal modes of alloy wheels which are made from Al7079+8% carbon fibres and other commonly used alloy wheel materials such as Steel Alloy, Forged steel, Magnesium alloy and Aluminium 7079.
Abstract: Alloy wheels used in automobiles differ from normal steel wheel rims with their increased strength to weight ratio, which improves the steering and overall performance of the system. Stiffness of the wheel rim is an important property of alloy wheels, which also influences the life of the wheel. Natural frequencies obtained from modal analysis can provide useful information about the stiffness of the design. The present study aims at assessing the material options for such wheels, based on their modal characteristics obtained using finite element analysis (FEA). Aluminium 7079 alloy reinforced with 8% carbon fibres (CF) is one of the optimised materials chosen for the study, mechanical properties of which are determined using tension test. Finite element model is developed to obtain the normal modes of alloy wheels which are made from Al7079 + 8% CF and other commonly used alloy wheel materials such as Steel Alloy, Forged steel, Magnesium alloy and Aluminium 7079. Modal analysis is carried out extracting the first ten natural frequencies and corresponding mode shapes. It is observed that Al7079 + 8% CF performs better by exhibiting higher frequencies than other materials.
3 citations
TL;DR: In this paper , a finite element analysis (FEA) model is developed to obtain the normal modes of alloy wheels which are made from Al7079 + 8% carbon fibres and other commonly used alloy wheel materials such as Steel Alloy, Forged steel, Magnesium alloy and Aluminium 7079.
Abstract: Alloy wheels used in automobiles differ from normal steel wheel rims with their increased strength to weight ratio, which improves the steering and overall performance of the system. Stiffness of the wheel rim is an important property of alloy wheels, which also influences the life of the wheel. Natural frequencies obtained from modal analysis can provide useful information about the stiffness of the design. The present study aims at assessing the material options for such wheels, based on their modal characteristics obtained using finite element analysis (FEA). Aluminium 7079 alloy reinforced with 8% carbon fibres (CF) is one of the optimised materials chosen for the study, mechanical properties of which are determined using tension test. Finite element model is developed to obtain the normal modes of alloy wheels which are made from Al7079 + 8% CF and other commonly used alloy wheel materials such as Steel Alloy, Forged steel, Magnesium alloy and Aluminium 7079. Modal analysis is carried out extracting the first ten natural frequencies and corresponding mode shapes. It is observed that Al7079 + 8% CF performs better by exhibiting higher frequencies than other materials.
2 citations
References
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15 Feb 2004-Materials Science and Engineering A-structural Materials Properties Microstructure and Processing
TL;DR: In this paper, the use of finite element technique for analyzing stress and displacement distributions in an aluminum alloy automotive rim-tire combination unit subject to the conjoint influence of inflation pressure and radial load is discussed.
Abstract: This paper presents and discuss the use of the finite element technique for analyzing stress and displacement distributions in an aluminum alloy automotive rim–tire combination unit subject to the conjoint influence of inflation pressure and radial load. The commonly used considerations in wheel design are elucidated. A viable and time-efficient technique for finite element modeling of a wheel (rim–tire unit), subjected to loading, is presented. The extrinsic influence of inflation pressure of the radial tire on wheel performance is discussed.
40 citations
TL;DR: In this article, the authors presented a reliable method for deriving a realistic load input at the rim using a heavy truck wheel as an example, where a physical tire model is derived from strain gauge measurements on wheels and a inverse FEM calculation.
Abstract: Nowadays, durability analyses of rotating suspension components are carried out by FEM. A reliable pre-design requires realistic customer usage conditions. One of the most important issues is the load transfer from the tire to the rim, which is decisively influenced by the kinds of tire construction, which differ depending on the vehicle type. The corresponding load conditions and load spectra also have to be taken into account. A comparison of numerical results and experimental sign-off tests from wheels and hubs in the biaxial test facility (ZWARP) - developed by the Fraunhofer LBF - is only possible by considering the issues described above. This paper shows a reliable method for deriving a realistic load input at the rim using a heavy truck wheel as example. A physical tire model is derived from strain gauge measurements on wheels and a inverse FEM calculation. Tire models and corresponding parameters are integrated in the LBF.WheelStrength and LBF.HubStrength. Additionally the software includes all customer usage conditions needed (load data, design spectra). These tools have been developed to simulate physical tests. The software calculates a local Required Fatigue Strength (RFS), for which the individual locations of the components are optimally dimensioned. These RFS values can be compared with strength data elaborated from fatigue tests on actual structures and include specific manufacturing influences. Subsequently such a numerical fatigue evaluation is carried out for verification of the newly developed commercial vehicle tire model. In the paper numerical and experimental results are presented displaying the accuracy of the method. With this technique a reliable approach for pre-design of commercial vehicle wheels and hubs has been created. The development process of wheels and hubs is substantially improved and optimized using the above-mentioned method.
9 citations
TL;DR: In this paper, an extensive finite element analysis of a vehicle wheel subject to the conjoint influence of inflation pressure and radial load (vehicle load) is reported, and the commonly used design co...
Abstract: An extensive finite element analysis of a vehicle wheel subject to the conjoint influence of inflation pressure and radial load (vehicle load) is reported in this paper. The commonly used design co...
8 citations