Parametric Design and Optimization of Alloy Wheel Based on Dynamic Cornering Fatigue Test

Abstract

This study proposes a parametric design and optimization technique for alloy wheels based on a dynamic cornering fatigue test. A case study of 13-inch diameter alloy wheels was considered based on the standard dynamic cornering test. The effect of the width and thickness of the wheel rim on the principal stress and fatigue life based on minimizing the weight is described for each scenario. A total of twenty-seven design of experiment are created and expanded in response surface and sensitivity analysis using Finite Element Analysis (FEA) software. The geometric parameter of alloy wheel reveal the surface response to principal stress and fatigue life. The rim width significantly displayed higher sensitivity than the thickness of allow wheel. The conclusion can be draw that the magnitude of maximum principal stress should not exceed as 145 MPa for passed the standard fatigue life of 100,000 cycles. The advantage of this parametric optimization technique is that it allows for an improved shape and size design process for alloy wheels.

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