Modeling and Fatique Analysis of Automotive Wheel Rim

Modeling and Fatique Analysis of Automotive Wheel Rim

Sreenivasulu. B Ch. Vijaya Kumar (M.TECH) CAD/CAM

1. ECH(Machine Design) student in TKR Engineering College Sphoorthy Engineering College MEERPET(V), Saroornagar Mdl, R.R Dist.

   ABSTRACT

   Wheel rim is one of the main parts which are used as protection for passengers from front and rear collision. The aim of this study was to analyze and study the structure and material employed for car wheel rim in one of the national car manufacturer. In this study, the most important variables like material, structures, shapes and impact conditions are studied for analysis of the wheel rim in order to improve the crashworthiness during collision. The simulation of a bumper is characterized by impact modeling using pro-e. According to the result of Displacement, stress of the wheel rim at various materials that is given in order to analyses the results. This speed is according to regulations of Federal Motor Vehicle Safety Standards, FMVSS 208- Occupant Crash Protection whereby the purpose and scope of this standard specifies requirements afford to protection for passengers. In this research, the four types of materials were selected the materials are alloy steel,aluminium alloy,magnesium alloy and forged alloy

   INTRODUCTION

   In hundreds of years ago humans was to make the wheel using wooden material and wheel rim are also same material as a wood to make the rim. After introducing reinforced material replace the material to make the wheel disc made of reinforced material. Spokes were replaced with a disc made of steel plate. This material still being used to in this days.

   Standard automotive wheel rim is made by rectangular sheet metal. The metal is bent to produce a cylindrical sleeve. Car wheels need to be durable and able to carry around weight. So we required materials are good stability and high strength, good durability.The rim of a wheel is the outer circular design of the metal on which the inside edge of the

   tyre is mounted on vehicles such as automobiles. A standard automotive steel wheel rim is made from a rectangular sheet metal. The metal plate is bent to produce a cylindrical sleeve with the two free edges of the sleeve welded together. To support the cylindrical rim structure, a disc is made by stamping a metal plate. It has to have appropriate holes for the center hub and lug nuts. The radial outer surface of the wheel disk has a cylindrical geometry to fit inside the rim. The rim and wheel disk are assembled by fitting together under the outer seat of the rim and the assembly welded together.

   In this project, wheel rim made of five materials that are steel alloy, aluminium alloy, and high-strength magnesium alloy is studied by crash simulation analysis to determine the stress, displacement. The main characteristics are compared between all the materials to find best material and structure. The results show that a magnesium alloy can minimize and reduce the stresses compare to other material. Commercial bumpers, Have studied that accidental always occur in front side. Applied load on rim in to ansys and meshed in order to get a simulation results. The energy absorption capability of the composite materials offers a unique combination of reduced weight and improves crashworthiness of the vehicle structures magnesium alloy rim show the good result for better performance compare to other materials.

   WHEEL RIM DIMENSIONS

   Outer diameter	450 mm
   Hub hole diameter	150 mm
   Bolt hole diameter	20 mm
   Rim width	254 mm

   MODEL OF THE RIM

   DISPLACEMENT PLOTS

   ALUMINIUM ALLOY

   displacement

   0.20

   0.02

   Resultant displacement

   aximum

   minmum

   type

   name

   Magnesium alloy

   name	type	minimum	maximum
   stress	Von-misses stress	0.02374	0.21 36

   FORGED STEEL

   name	type	minimum	maximum
   stress	Von-misess stress	0.0213	0.1923

   STEEL ALLOY
   name	type	minimu m	maxi
   DISPLACEME	RESULTAN T	0.018 mm	0.166 mm

   NT DISPLACE

   MENT

   ANALYSIS OF STRESSES STEEL ALLOY

   name	type	minimum	maximum
   stress	Von- misess	3.02 Mpa	140.056 Mpa

   ALUMINIUM ALLOY

   name	type	minimum	maximum
   stress	Von-misess	0.921	48.34

   name	type	minimum	maximum
   stress	Von-misess	0.6954	32.2 9

   MAGNESIUM ALLOY

   FORGED STEEL

   name	type	minimum	maximum
   s tress	Von-misess	2.452	135.93

   RESULD AND DISCUSSION

   Material properties

   Steel alloy:

   Youngs modulus (E) =2.34*105 N/mm2 Yield stress=240 N/mm2

   Density =7800kg/m3

   • Aluminum alloy:

     Youngs modulus (E) =72000 N/mm2

     Yield stress=160 N/mm2 Density =2800kg/m3

   • Magnesium alloy:

     Youngs modulus (E) =45000N/mm2 Yield stress=130 N/mm2

     Density =1800kg/m3

   • Forged steel:

Youngs modulus (E) =210000N/mm2 Yield stress=220 N/mm2

Density =7600kg/m3

Results obtained from softwares: Steel alloy:-

Von misses stress (v ) =140.056 N/mm2

Aluminum alloy:-

Von misses stress (v ) =48.326 N/mm2

Magnesium alloy:-

Von misses stress (v ) =32.204 N/mm2

Forged steel:-

Von misses stress (v ) =135.931 N/mm2 RESULT Table

CONCLUSION

1. The von misses stresses developed in steel alloy during static analysis is 140.056 N/mm2 at load 21.3KN the stress is below yield stress of material for these stress range we have to find at what numbr of cycles the component is yielding or crack is going to initiates

2. The von misses stresses developed in aluminum alloy during static analysis is

   48.326 N/mm2 at load 21.3KN the stress is below yield stress of material for these stress range we have to find at what number of cycles the component is yielding or crack is going to initiates

3. The von misses stresses developed in Magnesium alloy during static analysis is

   32.294 N/mm2 at load 21.3KN the stress is below yield stress of material for these stress range we have to find at what number of cycles the component is yielding or crack is going to initiates.

4. The von misses stresses developed in Forged steel during static analysis is 135.931 N/mm2 at load 21.3KN the stress is below yield stress of material for these stress range we have to find at what number of cycles the component is yielding or crack is going to initiates

5. From results we can make out, in steel alloy the Number of cycles to failure (Nf)= 2.17*105Cycles is greater than Aluminium, Magnesium, Forged steel. Hence Steel alloy is more feasible to use than aluminum.

6. Hence steel alloy have more life and durability compared to aluminum.

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CH.VIJAYA KUMAR(M.TECH) CAD/CAM

P.G Research scalar,