Abstract
Designing lightweight and comfortable automotive vehicles is a primary aim of the industry. Lightweight wheel designs can have a negative effect on the dynamic impact performance of the wheel; therefore, striking a balance between these two factors is a key objective in the design of automotive vehicles. Magnesium alloy wheels were investigated as magnesium alloy has damping performance advantages over some metal materials. Damping test methods were designed to establish the damping performance parameters of the magnesium alloy material. A finite element analysis model of magnesium alloy wheels was established with certain boundary conditions and constraints. The applicability of the model was verified by free modal evaluation of the wheel. Dynamic impact simulation analysis of the designed wheels was carried out, and the dynamic speed responses of magnesium alloy wheels under the impact of a dynamic load on the road surface were obtained. Comparison of the dynamic impact performance of magnesium and aluminum alloy wheels with the same structure showed that the magnesium alloy wheel achieved the target weight reduction of 32.3%; however, the dynamic impact performance was reduced. In order to realize the lightweight design, the dynamic impact performance of the magnesium alloy wheel should not be inferior to that of the aluminum alloy wheel; therefore, the design of the magnesium alloy wheel structure was optimized. The structural design optimization of the magnesium alloy wheel was carried out by defining the structural parameters of the wheel and using the acceleration and shock response of the wheel as the outputs. The optimization of weight reduction and dynamic impact performance of magnesium alloy wheels was achieved. Consequently, the designed magnesium alloy wheel was shown to have improved ride comfort while satisfying wheel structural performance standards and providing lightweight design.
Highlights
With the increasingly stringent regulatory requirements for energy conservation and emission reduction, there has been a significant increase in the use of magnesium as a structural material because of the lightness of magnesium alloys
A magnesium alloy wheel and excitation load application in the finite element model of the wheel are shown in Figures 7 and 8, respectively
In order to improve the ride comfort and reduce the weight of automotive vehicles, we designed a magnesium alloy wheel based on structural optimization and dynamic impact performance
Summary
With the increasingly stringent regulatory requirements for energy conservation and emission reduction, there has been a significant increase in the use of magnesium as a structural material because of the lightness of magnesium alloys. Magnesium alloys are structural materials with favorable properties such as low density, high specific strength, high specific stiffness, good vibration dampening characteristics, and excellent castability and have been extensively studied. Good damping capacity was demonstrated for AZ91 magnesium alloy. The wheel structure topology optimization method is used to optimize the wheel design to satisfy the lightweight and dynamic impact performance requirements. The designed magnesium alloy wheel was shown to have improved ride comfort while satisfying the requirements of wheel structural performance standards and lightweight design
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