Venkateswar Reddy and Praveen Paper

AIJREAS
VOLUME 5, ISSUE 7 (2020, JUL) (ISSN-2455-6300)ONLINE

Anveshana’s International Journal of Research in Engineering and Applied Sciences
DESIGN AND ANALYSIS OF WHEEL RIM

ANDDEVELOPMENT OFPROTOTYPEBYUSING3-
DPRINTER
MACHARLA ANIL
M.Tech,Assistant Professor, Department
of Mechanical Engineering , Mahaveer
Institute of Science & Technology,
Hyderabad.
INTRODUCTION
ABSTRACT: Thewheelisadevicethatenablesefficient
Importance of wheel in the automobile is movementofanobjectacrossasurfacewh
obvious.The vehicle may be towed without the
erethereisaforcepressingtheobjecttothes
engine but at the same time even that is also
urface.Earlywheelsweresimplewooden
not possible without the wheels, the wheels
along thetire has to carry the vehicle load,
diskswithaholefor the axle. Because of
provide cushioning effect and cope with the the structure of wood a horizontal slice
steering control.Generally wheel spokes are the of a trunk is not suitable, as itdoes not
supports consisting of a radial member of a have the structural strength to support
wheel joining the hubto the rim. The most
weight without collapsing; rounded
commonly used materials for making Wheel
pieces
spokes are with features ofexcellent lightness,
thermal conductivity, corrosion resistance, oflongitudinalboardsarerequired.Thesp
characteristics of casting, low temperature okewheelwasinventedmorerecently,and
,high damping property, machine processing allowedtheconstruction of lighter and
and recycling, etc. swifter vehicles. Alloy wheelsare
Presently,formotor cycles Aluminium alloy automobile wheels which
wheels are used,currently now replacing by aremadefromanalloyofaluminumormag
new magnesium alloy due its better properties nesiummetals(orsometimesamixtureofb
than Al-alloy. For design of the wheel rim catia
oth).Alloywheels differ from normal
isused. It is analyzed by using the ANSYS for
steel wheels because of their lighter
comparison of Al alloy wheel rim and Mg alloy
weight, which improves
wheel rimand Titanium alloy wheel.After
selecting the best design and converting that thesteeringandthespeedofthevehicle,ho
Catia file into STL file or saving file weversomealloywheelsareheavierthant
inSTLform.ThatSTLfileisusedfordirectdevelopin heequivalentsizesteelwheel.Alloywheel
gofprototyping modelbyusing FDM process.
sarealsobetterheatconductorsthansteelw
heels,improvingheatdissipation from
the brakes, which reduces the chance

EMAILID:anveshanaindia@gmail.com,WEBSITE:www.anveshanaindia.com
1
AIJREAS VOLUME 5, ISSUE 7 (2020, JUL) (ISSN-2455-6300)ONLINE
of brake failure in more evaluating the fatigue life

demandingdriving conditions. Over the ofaluminumwheelsisproposedinthatpaper.
years, achieving success in mechanical TheABAQUSsoftwarewasusedtobuildthest
design has been aticload finite element model of aluminum
madepossibleonlyafteryearsofexperien wheels for rotary fatigue test. Using the
cecoupledwithrigorousfield- methodproposed in this paper, the wheel
testing.Recentlytheprocedureshavesign life cycle was improved to over 1.0×105
ificantlyimprovedwiththeemergenceofi and satisfied
nnovativemethodonexperimentaland thedesignrequirement.Theresultsindicatedt
analyticalanalysis. hattheproposedmethodofintegratingfiniteel
2.LITERATURE REVIEW ementanalysis and nominal stress method
Awheelrimisahighlystressedcomponentina was a good and efficient method to predict
nautomobilethatissubjectedtoloads.Becaus the fatigue lifeof aluminum wheels.In this
eof the long life and high stresses, as well paper, for predicting the wheel fatigue life,
as the need for weight reduction, material the nominal stressmethodwas
andmanufacturing process selection is integratedintotheCAD
important in rim design. There are /CAEtechnologytosimulatetherotaryfatigue
competitions amongmaterials and test.Staticanalysis
manufacturing processes, due to cost
performance, and weight. This is a The wheel was constrained around
directresult of industry demand for flange edge of the rim and loaded with
components that are lighter, to increase a constantforce
efficiency, and attheendoftheshaft,seeFig.Theloadshaft
cheapertoproduce,whileatthesametimemai andwheelwereconnectedbybolts.Duetot
ntainingfatiguestrengthandotherfunctionalr hemainconcern being wheel
equirements.A paper published in the year deformation, the load shaft in the FEA
2009,which is about the fatigue analysis analysis was defined as a
ofaluminium wheel rim by Liangmo Wang rigidbody,usingtieconnectionwithwhee
- Yufa Chen - Chenzhi Wang - Qingzheng l.Jareaunderthewheelrimwasunderfullc
WangSchool of Mechanical Engineering, onstraints.Finite Element Analysis
Nanjing University of Science & (FEA) was first developed in 1943 by
Technology, China.Toimprove the quality R. Courant,
of aluminum wheels, a new method for whoutilizedtheRitzmethodofnumerical

2
analysisandminimizationofvariationcal ring,satisfyingthedesiredreliabilitywith
culustoobtainapproximatesolutionstovi weightsaving.
brationsystems.Shortlythereafter,apape 3.MODELINGOFWHEEL
RIMINCATIA:
rpublishedin1956byM.
J. Turner, R. W. Clough, H. C. Martin,

and L. J. Top established a broader
definition
ofnumericalanalysis.Thepapercenteredo
nthe"stiffnessanddeflectionofcomplexstr
uctures"
G HARINATH GOWD:During the

part of project a STATIC ANALYSIS
OF
LEAFSPRINGwascarriedoutusingFEA
package.The3dimensionalmodelofthele
afspringwasmodeled.Thenmodelwasme
shedinANSYS.Analysisfoundoutthetot
aldeformation,alternativestressbyusing
FEAsoftware.Andalsofoundoutthelife,s
afetyfactoranddamageofleaf spring
Fig 4.7 :3-DModelof5 Spokewheel
with MaterialManganeseSiliconSteel.
WU Li-hong1, LONG Si-yuan2, and The final result of a 5 spoke alloy

GUAN Shao-kang: Replacement of wheel , It was designed by Using
A365 CATIA V5
withAM60A,servicestressdistributionin softwareandthedesignisreadytogoto
thewheelbecomesmoreuniform,thepeak ANSYSforcomparisonofthesedesignin
valueoftheconcentratedstressreduceddu
todifferentmaterials.
etolowelasticmodulusofMgalloys.Thes
ervicestresslevelofredesignedMgwheeli
srelaxedfurtherbecauseofitsoptimizedst
ructurebyalteringthespokeconfiguration
andincreasingthefilletbetweenspokeand

3
Fig4.8:Final Resultof alloy wheel
4.STRUCTURAL ANALYSIS
Material Applied – Steel (MS)

4
Fig 4.3.Von – Mises Stress Diagram

Fig 4.1.Restraints / Clamps applied
Maximum Von Mises Stress found is
0.151MPa where as yield stress of Mild
Force of 98.1 N is applied – (As Mass of Air Steel is 276MPa. Hence the thickness
Purification Chamber is 10Kgs => 10 x 9.81 = chosen is more than sufficient to take
98.1N Force will be acting down words on 98.1N load (10 Kgs)
structure)
Maximum transitional displacement found is

0.000445 mm at 98.1 N forces which is very
Fig 4.2.Force of 98.1 N is applied
negligible
5.FABRICATION

5
PARTSASSEMBLY:
Wehavetakenanairpurifying
filterasshowninfigure(5.1).
Fig (5.1).AirPurifier
Wehaveplacedair purifyingfilterinsidethe
chamberasshownin figure (5.2).
Fig(5.2.)placing offilter
Wehavefittedtheexhaustwithafilteraswellfo
rbetterqualityofairasshowninfigure(5.3).
Fig(5.3)fixingoffilter
Fig (5.4). 3" Impeller Blower

FanBrush Less DC Motor 8Watts
Power and12volts Voltage.

6
Blower is equipment or a device which =0.000176x1500

increases the velocity of air or gas when it
=0.264 m3/min
is passed through equipped impellers.
They are mainly used for flow of air/gas Volumeofairinduced bythefan perhour
required for exhausting, aspirating,
= 0.264 x 60
cooling, ventilating, conveying etc. Blower
acts as a mediator for primary and = 15.896m3/hr
secondary filters.Fan Speed As volume of the air induced per hr
1500rpm,Energy required for the blower is
8W/hr is more than volume of the air to be
purified per hrtheselectedfan is
Wehavemountedsolarpanelonthetopoft
acceptable.
hestructurewithaselectricalconnections
SOLARPOWERCALCULATIO
asshownin figure(5.5).
N:
Fig(5.5).Fabrication of
solarairpurificationtower
6.SOLARAIRPURIFIERCALCULA
TIONS
Airto bepurified perhr=10m3/hr
SelectedFilterCapacity=15m3/hr
FilterParticulate
retentionsizeasperBSEN799=300nmor
0.3μm
RequireFan Capacity=10m3/hr
DiameterofFan (D)= 75mm
=0.075m
FanSpeed (N)=1500rpm
Widthofthefan(W)=40mm
= 0.04m
FanVoltage(V)=12V
Volumeoftheairinducedperrevolution(V) FanCurrent(I)=0.6Amp
=3.14x 0.0752x0.04/4 0.6Amp
=0.000176m3/rev PowerConsumptionofFan (Pf) =
Volumeofairinduced permin = Vx N

7
=VxI alloy material can be replaced with

optimized megnisium material because
=12 x 0.6
of its low deformation and elastic
=7.2Watt strain values. Compared to other
s
optimized materials like Titanium
~8Watts
alloy has low deformation value. So
the suitable material for alloy wheel is
Titanium alloy.At the end of the
CapacityofSelectedSolarPanel
project developed a prototype of
= 20Watts
designed wheel rim in catia v5 by 3-D
AsSolarPanelCapacityismorethantherequir
edfanpowercapacity,itisacceptable. printer.
7. CONCLUSION REFERENCES
Finally the wheel rim design is
1. M.Riesner and R. I. DeVries, ―Finite
completed successfully by using a Element Analysis and Structural
software of CATIA V5. And then the Optimization of VehicleWheels‖, in
Proceedings of International Congress
geometry of designed wheel rim is
& Exposition - SAE, Detroit, MI, 1993.
converted into Ansys 16.0 work bench.
It was analyzed by using the ANSYS 2. Ch. P.V. Ravi Kumar, Prof. R. Satya
16.0 for comparison of Al alloy wheel Meher. “Topology Optimization of
Aluminum Alloy Wheel”.International
rim & Mg alloy wheel rim and Ti alloy Journal of Modern Engineering
wheel. Research, Ruzanna Nadia Binti Nisah,
Finite elementAnalysis of a Motorcycle
Analysis results from testing the alloy
Alloy Wheel. Generated by Foxit
wheel under static load containing the Creator.
stresses and deflection are listed in the
Table. The materials we analyze are 3. Mohd Izzat Faliqfarhan and Bin
Baharom (2008), “Simulation Test of
Aluminium alloy, magnesium alloy, Automotive Alloy Wheel Using
Titanium alloy. The analysis of alloy Computer Aided Engineering
Software”, Eng. D. Thesis.
wheel we found that the magnesium
alloy wheel have a good strength and it
4. Liangmo Wang, Yufa Chen, Chenzhi
have a less deformation under the Wang and Qingzheng Wang (2011),
fixed support and force, than the other “Fatigue Life Analysis ofAluminum
Wheels by Simulation of Rotary
three material which are used for alloy Fatigue Test”, Strojniski Vestnik-
wheels. So the existing aluminium Journal of

8
MechanicalEngineering,University
Malaysia, Pahang.
5. Si-Young Kwak, Jie Cheng and

Jeong-Kil Choi (2011), “Impact
Analysis of Casting Parts Considering
Shrinkage Cavity Defect”, China
Foundry,
6. WenRu Wei, Liang Yu, Yanli Jiang,

JunChuan Tan and Ru HongQiang
(2011), “Fatigue Life Analysis of
Aluminum HS6061- T6 Rims Using
Finite Element Method”, International
Conferenceon Remote Sensing,
Environment and Transportation
Engineering
15.896m
.896m
=
15.896m
5.896m
==
0.264 m
0.264

9

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AIJREAS

VOLUME 5, ISSUE 7 (2020, JUL) (ISSN-2455-6300)ONLINE

DESIGN AND ANALYSIS OF WHEEL RIM

Anveshana’s International Journal of Research in Engineering and Applied Sciences

of brake failure in more evaluating the fatigue life

Anveshana’s International Journal of Research in Engineering and Applied Sciences

J. Turner, R. W. Clough, H. C. Martin,

G HARINATH GOWD:During the

WU Li-hong1, LONG Si-yuan2, and The final result of a 5 spoke alloy

Anveshana’s International Journal of Research in Engineering and Applied Sciences

Fig4.8:Final Resultof alloy wheel

Material Applied – Steel (MS)

Anveshana’s International Journal of Research in Engineering and Applied Sciences

Fig 4.3.Von – Mises Stress Diagram

Maximum transitional displacement found is

Anveshana’s International Journal of Research in Engineering and Applied Sciences

Fig (5.4). 3" Impeller Blower

Anveshana’s International Journal of Research in Engineering and Applied Sciences

Blower is equipment or a device which =0.000176x1500

Airto bepurified perhr=10m3/hr

DiameterofFan (D)= 75mm

Anveshana’s International Journal of Research in Engineering and Applied Sciences

=VxI alloy material can be replaced with

Anveshana’s International Journal of Research in Engineering and Applied Sciences

5. Si-Young Kwak, Jie Cheng and

6. WenRu Wei, Liang Yu, Yanli Jiang,

Anveshana’s International Journal of Research in Engineering and Applied Sciences

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