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Characterization Study and Fabrication of Aluminium Bronze Wheel Rim for

Automobile

Article  in  International Journal of Vehicle Structures and Systems · June 2020

DOI: 10.4273/ijvss.12.1.13

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Sathyabama Institute of Science and Technology
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 Yuvaraja et al. 2019. Int. J. Vehicle Structures & Systems, 12(1), 61-64
Int ernat i onal Journal of
ISSN: 0975-3060 (Print), 0975-3540 (Online)
doi: 10.4273/ijvss.12.1.13 Vehicle Structures & Systems
Available online at www.maftree.org/eja
© 2020. MechAero Foundation for Technical Research & Education Excellence

Characterization Study and Fabrication of Aluminium Bronze Wheel Rim for

Automobile
S. Yuvarajaa and Dillip Kumar Sahoob
Dept. of Automobile Engg, Sathyabama Inst. of Sci. & Tech., Chennai, Tamil Nadu, India
a
Corresponding Author, Email: yuvar_1985mech@yahoo.co.in
b
Email: dillipkumarsahoo@gmail.com

ABSTRACT:
The wheel rim plays a vital role for good running of the vehicle and the most important safety components from a
structural point of view. It must be made with adequate strength and lighter in weight to reduce the unsprung mass of
the vehicle and plays a major role in vehicle dynamics. The present study deals with the comparison of structural
analysis of aluminium bronze alloy wheel rim with three different compositions to enhance corrosion and fatigue
resistance. The design of the wheel rim was created by CATIA V5 and structural behaviour was analysed by ANSYS
workbench. The results showed that combination of 90% Al alloy and 10% CuSn) gives adequate strength compared to
other combinations of aluminium and bronze. The fabrication of the rim was done by casting methods. Various test like
impact, shear, hardness & ultimate tensile tests were conducted to know the mechanical strength of the rim. Salt spray
corrosion test was carried out to know the corrosion behaviour of the rim and the results show that no corrosion was
found up-to 240 hours.

KEYWORDS:
Wheel rim; CATIA V5; Fabrication; Impact test; Salt spray test

CITATION:
S. Yuvaraja and D.K. Sahoo. 2020. Characterization Study and Fabrication of Aluminium Bronze Wheel Rim for
Automobile, Int. J. Vehicle Structures & Systems, 12(1), 61-64. doi:10.4273/ijvss.12.1.13.

durability analysis (fatigue life predication) and

1. Introduction reliability method for dealing with variations inherent in
engineering structure have been applied to the
The rim of a wheel is the outer circular design of the
automotive wheel. Kale et al [1] presented various
metal on which the inside edge of the tyre is mounted on
materials used for wheel rims and analysed extensively
vehicles such as automobiles. For example, in a four-
about their properties like thermal conductivity,
wheeler, the rim is a hoop attached to the outer ends of
corrosion resistance, price, availability, manufacturing
the spokes-arm of the wheel that holds the tyre and the
processes, advantages and disadvantages of materials.
tube. A wheel rim is a highly stressed component in an
Srinivasa et al [2] analyzed various forces and moments
automobile, subjected to bending and torsional loads.
acting on wheel rim by design software Creo 2.0. Static
Because of the long life and high stresses, as well as the
and dynamic analysis was made by corresponding
need for weight reduction, material and manufacturing
mechanical properties and their chemical composition by
process selection is important in rim design. There are
using ANSYS 17.0. Ashok kumar et al [3] studied the
competitions among materials and manufacturing
comparison of disc wheel rim made by aluminium and
processes, due to cost performance and weight. This is a
forged steel by ANSYS software and claimed that forged
direct result of industry demand for components that are
steel-based rim has less deflection that aluminium based
lighter, to increase efficiency and cheaper to produce,
wheel rim.
while at the same time maintaining fatigue strength and
Antony et al [4] modelled wheel design of two-
other functional requirements. Automotive wheels have
wheeler by applying different loads and pressures on
evolved over the decades from early spoke designs of
different material compositions and also done the static
wood and steel. Carryovers from wagon and bicycle
& dynamic analysis of the wheel by NX NASTRAN
technology to flat steel discs and finally to the stamped
software. Yadav et al [5] optimised the passenger car by
metal configurations, modern cast and forged aluminium
finite element methods to minimise the rim weight
alloy rims of today’s modern vehicles.
without exceeding allowable strain and compared with
Historically, successful designs arrived after years
experimental data. Chaitanya et al [6] developed wheel
of experience and extensive field testing. Since the
rim with polymer matrix polymer composites (PMPC)
1970s, several innovative methods of testing well aided
materials, performed mass optimization and suggested
with experimental stress measurements have been
that PMPC with 30% carbon reinforcement is the best
initiated. In recent years, the procedures have been
materials to replace aluminium alloy. Radhakrishnan et
improved by a variety of experimental and analytical
al [7] has provided total system approach to new
methods for structural analysis. Within the past 10 years,

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