Development and Application of Light-Weight Design of the Aluminum Alloy Wheel

Hu, Jin Hua; Liu, Xinxin; Sun, Hong; Zhu, Zhi Hua; Li, Bao Hua

doi:10.4028/www.scientific.net/amm.310.253

Cited by 8 publications

(4 citation statements)

References 5 publications

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“…With reference to the literature [31,32], the meanings and values of the symbols in Equations ( 1)-( 14) can be determined (Table 3). By substituting the values in Table 3 into Equations ( 1)-( 14), the comprehensive carbon emission benefit of the wheel hub after the application of the lightweight design can be determined, as shown in Equation (15). Meanwhile, the carbon emission benefits of each part caused by the lightweight design can be obtained, as shown in Table 4.…”

Section: Carbon Emission Resultsmentioning

confidence: 99%

“…Pang et al [14] established a response surface model between dimensions and structural properties of the spokes and hubs for the purpose of parameter optimization to achieve the lightweight property. Hu et al [15] optimized the parameters of a certain type of aluminum alloy wheel hub by regarding the thicknesses of the wheel and the rim as the design variables and the minimum mass of the wheel as the goal. Chai et al [16] designed a lightweight wheel hub formed of a composite whose thermoplasticity was enhanced using long glass fiber and studied its fatigue life by means of simulation and experiments.…”

Section: Introductionmentioning

confidence: 99%

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Analysis Method and Case Study of the Lightweight Design of Automotive Parts and Its Influence on Carbon Emissions

Zhang

Wang

2022

Processes

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The automobile industry, as a representative in pursuing the goals of “emission peak” and “carbon neutrality”, has made low carbon a new industrial practice. With regard to low carbon, the lightweight design proves to be an effective approach to reducing carbon emissions from automobiles. Given the state of research, in which the existing lightweight design schemes of automobiles seldom consider the impact of the lightweight quality on carbon emissions during the whole life cycle of the automobiles, this paper proposes a more comprehensive lightweight design method for automobiles in regard to carbon emissions. First, the finite element method was adopted to analyze the stress, strain and safety factors of the automobile parts based on their stress, so as to identify the positions where the lightweight design was applicable. Subsequently, a lightweight scheme was designed accordingly. Next, the finite element method was re-applied to the parts whose weights had been reduced. In this way, the feasibility of the lightweight scheme was verified. In addition, a method of calculating the carbon emissions produced by changes in the mass, manufacturing processes, application and recycling of automobile parts after the application of the lightweight design was also presented. The method can be used for evaluating the low carbon benefits of the lightweight design scheme. To prove the feasibility of the method, the ZS061750-152101 wheel hub designed and manufactured by Anhui Axle Co., Ltd. was taken as an example for the case analysis. The lightweight design changes three structures of the wheel hub, reducing its weight by 1.4 kg in total. For a single wheel hub, the carbon emissions are reduced by 51.22 kg altogether. That is to say, if the lightweight scheme were to be applied to all the wheels produced by Anhui Axle Co., Ltd. (about 500,000 per year), the carbon emissions from the wheel production, application and recycling could be cut by 2.56 × 107 kg, marking a favorable emission reduction effect. The proposed method can not only provide insight into the lightweight design of automobiles and other equipment against the background of low carbon but also provide a channel for calculating the carbon emission changes in the whole process after the application of the lightweight design.

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Section: Carbon Emission Resultsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Analysis Method and Case Study of the Lightweight Design of Automotive Parts and Its Influence on Carbon Emissions

Zhang

Wang

2022

Processes

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“…Compared to traditional die-castings, the aluminum alloys used in automotive structural components require higher standards in terms of connection processes, overall vehicle durability, and safety. Therefore, the use of high-strength, tough, and heat-treated AlSi10MnMg alloys in high-vacuum die-casting is often preferred for manufacturing automotive structural components [4]. As deformation and bubble defects resulting from heat treatment are inevitable, there is a pressing need to develop heat-treated material that avoids defects introduced during heat treatment, such as pores, thermal cracks, dimensional changes, and deformations, thereby reducing energy consumption and environmental pollution [5].…”

Section: Introductionmentioning

confidence: 99%

Design and Optimization of Casting System for Integrated Longitudinal Beam and Tower Package Based on Al-Si Alloy

Heng,

Nan,

Xingyu

et al. 2024

Adv. Sci. Technol. Res. J.

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This study optimized the integrated die-casting of an aluminum alloy longitudinal beam and tower component using no heat-treated aluminum alloy. Leveraging material properties and part geometry, a pouring system was designed and refined through mold flow analysis. This optimized the velocity, temperature distribution, and air entrapment to reduce defects like shrinkage porosity. The optimized pouring parameters were 695 °C melt temperature, 210 °C initial mold temperature, and 4.9 m/s shot speed. This reduced shrinkage porosity by 10.4% versus the original design. Die-casting trials with the optimized pouring system produced defect-free castings. The critical load-bearing section of the die casting had a yield strength of 184 MPa and elongation of 10.9%, which can meet the production requirements. In summary, based on the optimization of pouring system by mold flow analysis, by developing the integrated die casting process for aluminum alloy, not only are the defects eliminated, but also the castings with sufficient mechanical properties are produced.

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“…Zhuang [19] carried out the topology optimization of aluminum alloy wheels, the strength and stiffness of the optimized wheels were simulated and analyzed. Hu [20] optimized the aluminum alloy wheel use the wheel rim and flange thickness as the design variables, the maximum stress of the wheel in bending fatigue and radial fatigue conditions as the constraint, and aiming at the smallest wheel quality, the aluminum alloy wheel optimized. Based on the bending fatigue test, Xiao [21,22] carried out topology optimization on steel wheels, and designed the lightweight design of the wheels with flexibility and modal frequency as the target, and carried out stress analysis and experimental verification.…”

Section: Introduction mentioning

confidence: 99%

Multi-objective Optimization Design of Magnesium Alloy Wheel Based on Topology Optimization

Jiang¹,

Liu²,

Fukushima³

et al. 2019

JMSE-B

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Lightweight of automatic vehicle is a significant application trend, using topology optimization and magnesium alloy materials is a valuable way. This article designs a new model of automobile wheel and optimizes the structure for lightweight. Through measuring and analyzing designed model under static force, clear and useful topology optimization results were obtained. Comparing wheel performance before and after optimization, the optimized wheel structure compliance with conditions such as strength can be obtained. Considering three different materials namely magnesium alloy, aluminum alloy and steel, the stress and strain performances of each materials can be obtained by finite element analysis. The reasonable and superior magnesium alloy wheels for lightweight design were obtained. This research predicts the reliability of the optimization design, some valuable references are provided for the development of magnesium alloy wheel.

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Development and Application of Light-Weight Design of the Aluminum Alloy Wheel

Cited by 8 publications

References 5 publications

Analysis Method and Case Study of the Lightweight Design of Automotive Parts and Its Influence on Carbon Emissions

Analysis Method and Case Study of the Lightweight Design of Automotive Parts and Its Influence on Carbon Emissions

Design and Optimization of Casting System for Integrated Longitudinal Beam and Tower Package Based on Al-Si Alloy

Multi-objective Optimization Design of Magnesium Alloy Wheel Based on Topology Optimization

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