Finite Element Analysis on

hybrid composite Wheel Rim

Aim of the project
• Main aim of the project is developing low cost, light weight ,Hight
strength Fiber Reinforced Composite Material for Alloy wheel rim
 Introduction
1.The automotive industry faces increasing pressure to maximize performance while minimizing
weight and cost to produce more fuel efficient vehicles
2.wheel rim assembly contributes the major weight addition in motorcycle after engine. To
overcome this disadvantage alloy wheels are invented. While comparing all alloy materials
aluminium alloy is the best of other alloy materials
3.For Further invention to reducing vehicle weight is ,that developing low density high stiffness
material
4.Composite material will give low weight and high strength to components
5.Generally composite materials are lighter and stronger than conventional metals.
6.In this Project implementing two different categories fiber reinforced composite material
•
Wheel Rim
• Al-based Wheel Rim
Objective of the project
1. Developing new low price ,lightweight Two wheeler alloy wheel rim
two wheel
2. Making Fiber reinforced composite(FRC) by artificial fiber and natural
fiber
3. Result validation of both, existing and FRC material by Finite Element
method
4. Alloy Wheel Rim Model Designed by CATIA V5 design software
5. In this project model is designed for Alloy wheel Rim used in two
wheeler by collecting data from reverse engineering process from
existing model
 Objective of the project

6.investigation of current rims to find out their current structural

properties;
7.Design is evaluated by analysing(FEM) through existing and FRC
material the model by taking the constraints as ultimate stresses
and variables as alloy materials and different loads
8.Final Fem Result comparing with Al-alloy and FRC
 Problem identification:

• The weight of the conventional wheel rim is relatively high

• Rims made of metals and metal alloys are highly prone to corrosion
• Manufacturing of the rims involves high consumption of time and requires
more man power
• Machining process of conventional rim is more complicate and requires high
skilled workers to do the operation.
• It is difficult to identify the small deformation in the conventional rim caused
due to sudden impact.
• Costs of the metal rims are comparatively high.
Scope of the project
• This project will contribute to a variety of projects intended to
decrease the weight and increase the performance
• The combined decrease in weight will allow improved vehicular
acceleration capability thereby reducing lap times and improving
handling,
Literature review
• M. Sabari et.al (2015) has studied the comparative study of car wheel rim materials for its deformation with the help of FEA methods. In his study he
considered two materials namely carbon steel and aluminium alloy. CAD model of both material has drafted using Solid works software and then analysis
performed by using CATIA software. In this research researcher changed the two parameters such as load applied and speed of wheel rim. By changing load
and cruising speed rims has analyzed also graph of maximum displacement against speed plotted and it is found that as speed increases displacement of
both material increases. Displacement in alloy wheel rim is more than the steel.
• Sourav Das (2014) has studied the design and weight optimization of sport utility car wheel rim by taking AlSi7Mg0.3 aluminium alloy wheel. According to
researcher and wheel rim material manuals aluminium alloys, magnesium alloys are light in weight, very good heat conductor as well as excellent aesthetic
appearance. Ductility of magnesium alloys is very low as compared to aluminium alloys. Also magnesium rims are not repairable after it’s bending
• WU Li-hong1, LONG Si-yuan2, and GUAN Shao-kang: Replacement of A365 with AM60A, service stress distribution in the wheel becomes more uniform, the
peak value of the concentrated stress reduced due to low elastic modulus of Mg alloys. The service stress level of redesigned Mg wheel is relaxed further
because of its optimized structure by altering the spoke configuration and increasing the fillet between spoke and ring, satisfying the desired reliability with
weight saving
• WU Li-hong1, LONG Si-yuan2, and GUAN Shao-kang: Replacement of A365 with AM60A, service stress distribution in the wheel becomes more uniform, the
peak value of the concentrated stress reduced due to low elastic modulus of Mg alloys. The service stress level of redesigned Mg wheel is relaxed further
because of its optimized structure by altering the spoke configuration and increasing the fillet between spoke and ring, satisfying the desired reliability with
weight saving
 
• N. Satyanarayana&Ch.Sambaiah: During the part of project a static analysis of aluminum alloy wheel A356 was carried out using FEA package. The 3
dimensional model of the wheel was designed using CATIA. Then the 3-D model was imported into ANSYS using the IGES format. We find out the
total deformation, alternative stress and shear stress by using FEA software. And also we find out the life, safety factor and damage of alloy wheel by
using S-N curve. S-N curve is input for an A.356.2 material. For a wheel maker, reduction in the development time means a reduction in the cost.
Hence, to find an effective way of static analysis which can be equivalent to the same impact effect of dynamic loading is an important issue
Methodology

Concept
CAD Material FEM Result &
of the
Design Selection Solutions Discussion
Project
Software used
• CAD-CATIA V5
(Design software-3D level modelling from various vehicle reference
data collection )

Analysis(FEM) Solver- Ansys-16.2(Static structural-based Solving)