Reverse Modeling and Topological Optimization for Lightweight Design of Automobile Wheel Hubs with Hollow Ribs

Abstract

Lightweight of wheel hubs is the linchpin for reducing the unsprung mass and improving the vehicle dynamic and braking performance of vehicles, thus, sustaining stability and comfortability. Current experience-based lightweight designs of wheel hubs have been argued to render uneven distribution of materials. This work develops a novel method to combine the reverse modeling technique with the topological optimization method to derive lightweight wheel hubs based on the principles of mechanics. A reverse modeling technique is first adopted to scan and reproduce the prototype 3D geometry of the wheel hub with solid ribs. The finite element method (FEM) is then applied to perform stress analysis to identify the maximum stress and its location of wheel hub under variable potential physical conditions. The finite element model is then divided into optimization region and nonoptimized region: the former is the interior portion of spoke and the latter is the outer surface of the spoke. A topology optimization is then conducted to remove the optimization region which is interior material of the spokes. The hollow wheel hub is then reconstructed with constant wall thickness about 5[Formula: see text]mm via a reverse modeling technique. The results show that the reconstructed model can reduce the mass of 12.7% compared to the pre-optimized model. The present method of this paper can guarantee the optimal distribution of wheel hub material based on mechanics principle. It can be implemented automatically to shorten the time interval for optimal lightweight designs. It is especially preferable for many existing structures and components as it maintains the structural appearance of optimization object.

The Present Situation of Lightweight Technology and Its Application and Thinking in Agricultural Equipment

“…Wei Chunmei [54] et al conducted topology optimization for the 3D modeling of flange fork, spline shaft fork and other parts of the transmission shaft of heavy duty vehicles, which ultimately not only reduced the weight of the parts, but also made the parts meet the design requirements. Literature [55] carried out the lightweight design for the hub, and finally realized the lightweight design of the hub by combining reverse modeling technology with topology optimization method. Xue Yajun [56] et al carried out lightweight design for the suspension bracket of tilting plough, and realized the lightweight of the suspension bracket of tilting plough by combining topology optimization and genetic algorithm.…”

Fatigue life optimization and lightweight design of wheel based on entropy weight grey relation analysis and modified NSGA-II

“…In terms of wheel optimization design, Jiang et al 15 optimized the structure design of magnesium alloy wheel, which not only realized the weight reduction of wheels but also optimized the dynamic impact performance. Xu et al 16 combined reverse modeling technology with topology optimization method, derived lightweight wheels according to mechanical principles and the wheel mass was reduced by 12.7%. Wang et al 17 designed a dissimilar steel assembly wheel with B500CL inner rim and Q345B outer rim, in which inner and outer rims are connected by bolts.…”

Lightweight Design of Special Axle Hub Based on ANSYS Consider Different Working Conditions for Low Carbon

“…A lightweight designed monobloc ngered hub is studied by Topouris and Tirovic [11], aiming at reducing disc mass but maintaining rotor thermal capacity. Combine the reverse modeling technique with the topological optimization method to derive lightweight wheel hubs based on the principles of mechanics by Xu et al [12]. Considering stress and fatigue life, a lightweight design of the axle hub based on ANSYS is studied by Zhang et al [13].…”