Multi-objective optimization design of wheel based on the performance of 13° and 90° impact tests

Abstract

In order to study the fatigue, 13° impact and 90° impact performance of wheel and propose a wheel structure design and optimization method based on these performance, taking a type wheel as research objects, united topology optimization was performed based on dynamic bending and radial fatigue tests, and an assembled wheel with a magnesium alloy rim and an aluminum alloy disc was designed. Finite element models of the assembled wheel for 13° impact tests were established to analyze the effective plastic strain of the wheel under two conditions of the hammer facing the spoke and the window respectively. And established finite element models of the assembled wheel for 90° impact tests, analyzed the deformation of the inner wheel flange and the effective plastic strain of the rim and disc when the hammer impacted facing the window, and analyzed the failure range of the wheel and the effective plastic strain of the rim and disc beyond the 25% circumferential range (90°) of the impact position when the hammer impacted facing the valve window. Then studied the relationship between these performance and the wheel structure. The parametric models of the assembled wheel under four finite element conditions were established with 12 design variables defined by using the mesh morphing technology. The Optimal Latin Hypercube design and Hammersley design were used to fit the Kriging surrogate model and to validate the precision of the surrogate model in Isight software platform where the DEP-MeshWorks and LS-DYNA software were integrated. Using the established surrogate model, Non-dominated Sorting Genetic Algorithm-II (NSGA-II) was adopted to perform the multi-objective optimization of the wheel. The Pareto frontier was obtained, and a compromise solution was selected as the optimal design result. The weight of the optimized assembled wheel was 28.59% less than that of the same type cast aluminum alloy wheel. Test the optimized wheels referencing four finite element conditions, and validate the correctness of finite element models by comparing the simulation and test values of equivalent strain and maximum acceleration on measuring points. The simulation analyses were in agreement with the test results. A wheel structural design process and multi-objective optimization method based on the fatigue, 13° impact and 90° impact tests performance were realized in this article, providing the theoretical and technical basis for wheel optimization design.