Alloy Wheel Research Articles

Numerical simulation on 90° impact test of aluminium alloy wheel with the effect of tyre

Car wheels are crucial to automobile safety, requiring a rigorous test before production. A 90° impact test simulates the frontal impact and its influences on the wheel structure, replicating dynamic driving conditions. A novel modelling approach is illustrated for the 90° impact test simulation and investigates the feasibility of excluding the tyre. Firstly, the test performs and validates five impact simulations, with the maximum deformation error being 7.04%. Subsequently, with additional tests, the effectiveness of the modelling approach is evaluated. Lastly, the effect of tyres has been analysed from an energy perspective. The results indicate that the tyre significantly influences the simulation results and should be included in the finite element (FE) model, which differs from the 13° impact test.

Cooling System of A High-Pressure Centrifugal Compressor: Development and Impact on Wheel Temperatures (GT2024-121464)

Abstract High power density, low fuel consumption, and a compact design with competitive total costs of ownership are key requirements for internal combustion engines for conventional fuels and carbon-free or carbon-neutral future fuels. These requirements influence the development targets of charging systems and call for single-stage charging systems with increased charge air pressures. However, high compressor pressure ratios of the turbocharger lead to challenging material temperatures in aluminum alloy wheels. Consequently, creep becomes the fundamental lifetime-limiting damage mechanism for these wheels. In order to meet customer requirements regarding total costs of ownership, the lifetime is of major importance for the development of aluminum compressor wheels for turbochargers with pressure ratios beyond 6. This paper focuses on a high-pressure compressor design with a water-cooling system for a new turbocharger generation. The development of its components and their validation based on numerically predicted and measured wheel temperatures are discussed. After introducing the need for high-pressure ratios and the accompanying lifetime challenges, the paper presents the design strategy and methods of the development process. Finally, the paper summarizes the achievements obtained by this procedure. Detailed and rarely before documented temperature measurements from the rotating compressor wheel are published. As will be shown, the temperature measurements confirm the predictions from the pre-development phase. A comparison of the temperature measurements from the recently developed wheel with measurements carried out for a state-of-the-art wheel reveals the improvements achieved by this new generation of high-pressure compressors.

Reliability assessment of additively manufactured TB6 titanium alloy wheel hubs

The strength and reliability of the additively manufactured titanium alloy wheel hub have been investigated and analyzed. The running speed of the supercar, which utilizes the additively manufactured titanium alloy wheel hub, is divided into three levels. The impact power on the wheel hub is computed for each speed level. Then, the maximum stress of the wheel hub under each level of impact is obtained using finite element analysis. Formulas for calculating the residual strength and reliability under each level of fatigue impact are provided. Additionally, formulas for calculating residual strength and reliability of wheel hubs, considering the random cross occurrence of the three types of impacts, are given. Finally, the changes in residual strength and reliability are analyzed. This method is not only suitable for the reliability calculation of additively manufactured titanium alloy wheels but also applicable to the reliability calculation of other alloy wheels.

3D finite element analysis of carbon fiber reinforced aluminium alloy wheel

3D finite element analysis of carbon fiber reinforced aluminium alloy wheel

Effect on the physical field of the die during the backward extrusion process of magnesium alloy wheel

The eccentric placement of billets reduces the service life of the dies, and at the same time causes the scrapping of the wheel blanks. However, for axisymmetric forgings, eccentric placement is unavoidable. In this study, the mutual effects between the billet and the die during backward extrusion of magnesium (Mg) alloy wheels are analyzed by physical and numerical simulations, focusing on the effects on the physical field of the die. There were dangerous points in the design of the combined die structure and the lower mating surface of the female die and the bottom die were prone to stress concentration during the filling process of the Mg wheel, which led to the cracking of the die. The eccentric extrusion of the wheel resulted in a slope in the filling height of the rim, and it had a great effect on the physical field and microstructure distribution at the same time, which in turn affected the physical field distribution of the wheel die, resulting in uneven load distribution at the lower rim of the die and reducing the life of the combined die. The combined die structure optimization solution can process the female die into a curved surface along the fracture surface and at the same time process a hollow circular table to cooperate with the bottom die and the female die.

Structural computational analysis of conventional and self-designed rover wheel architectures for extraterrestrial roving application

The technical advancements in robotics have closely been followed by developments in aerospace excavation robots. This research elucidates self-designed shape memory alloy wheels for their use in Lunar Excavations, which attributes to the new era of space exploration robots. The wheel design proves to be of paramount importance as crucial operations such as mobility, steering, and traction control build upon wheel design. A comparison has been made between Aluminium alloy, Structural Steel, and Shape Memory alloy (Nitinol) wheels for both conventional and self-designed wheel architectures. Wheel architecture tests and their results are articulated with the aid of simulation. The significant performance parameters, primarily Total Deformation, Equivalent Stress, and Shear stress-induced, were analyzed, which articulates the performance of the wheel at the time of landing. It was observed that for both wheel designs: self-designed and conventional, the maximum total deformation was 0.011154 mm and 1.3573 mm, respectively, when Aluminium alloy was chosen as the base material. For Steel and Nitinol, the self-designed wheel structure proved to perform better than the conventional wheel design with lower values of total deformation (0.0041129 mm and 0.010968 mm, respectively).

Physical field regulation of magnesium alloy wheel formed by backward extrusion process with multi-stage variable speed

To reduce the tonnage required during the forming process of magnesium (Mg) alloy wheels by backward extrusion (BE) and refine the grains at the wheel bottom, the multi-stage variable (MSV) speed process is proposed based on the characteristics of Mg alloy wheels formed by BE. A numerical model for the BE process of Mg alloy wheels using the Defrom-3D was constructed, and the effects of constant speed and MSV speed processes on the physical fields and DRXed grain size evolution during the forming of Mg alloy wheels were investigated. Lastly, the simulation results were indirectly verified by industrial trial production. The results show that constant speed extrusion has a small effect on the effective stress, but a large effect on the wheel temperature distribution, where the forming speed of the upper rim plays a decisive role in the final temperature distribution of the wheel. MSV speed process is used to regulate the physical field evolution during wheel forming based on the effect of constant speed on the physical field of the wheel. With the high-speed forming of the rim and low-speed forming of the upper wheel rim (9-9-1 mm/s), the temperature and effective stress distribution of the wheel blank are reasonable while reducing the forming tonnage and refining the grains at the wheel bottom.

Improving heat transfer and compressed air consumption in low pressure die casting of aluminum wheels

Automotive wheels made from aluminum alloys are generally manufactured using the Low-Pressure Die Casting (LPDC) method. The molten aluminum is pressurized and filled into the cavities between the molds, and it is cooled using cooling channels in the LPDC. While the cooling fluid can be either air or water in industrial applications, only air cooling is utilized within the scope of this study. The primary expenditures of the process are attributed to the cycle time and the consumption of compressed air. In industrial settings, the primary coolant supply, emanating from either one or two inlet sources, is systematically channeled through a series of nozzles. These nozzles are strategically designed to impinge air onto specific areas of the mold pockets, ensuring efficient cooling.This research focuses on enhancing the cooling channels and mold pocket regions in LPDC through a combination of experiments and Computational Fluid Dynamics (CFD) integrated with Conjugate Heat Transfer (CHT) analyses. The study involves designing cooling channels to achieve a uniform mass flow distribution at the nozzle outlets, and optimizing the mold pocket regions. This optimization resulted in a 46% reduction in compressed air flow while maintaining comparable levels of heat transfer in the optimized mold pocket design. Moreover, flow rate non-uniformity at nozzle outlets was reduced from 11.5% to 2.0% to achieve uniform cooling and temperature distribution across the wheel spokes. An experimental setup with a cooling pipe network allowed simultaneous flow rate measurements from 20 outlets using flow rate sensors.The improved cooling channel and mold pocket design were adapted to the LPDC, and 20 aluminum alloy wheels were successfully cast with a 46% lower mass flow rate. All these wheels were tested in accordance with the relevant test specifications and the results obtained were assessed as compliant according to certain limits.

Corrosion, wear and machinability studies on scrap aluminium alloy wheel based metal matrix composite

Recycled materials, especially scrap aluminum alloy wheels with reinforcement castings, are gaining applications in various fields such as aerospace, naval, military, and automobile. In this research, Honda car alloy wheels are stir-cast with 5% alumina as reinforcement and subjected to corrosion, wear, and machinability studies. Corrosion studies were conducted to evaluate the corrosion current density (ICorr), corrosion potential (ECorr), and corrosion rate for the cast aluminum metal matrix composite. The wear studies with different loads, i.e., 50 N, 60 N, 70 N, and 80 N, were performed on the specimen and investigated the coefficient of friction, frictional force, and pin temperature. The sliding load has a significant effect on wear performance, and for the sliding load of 80 N, the wear recorded was 2574.83 µm. The electrochemical machinability studies with voltage, duty cycle, and concentration of citric acid electrolyte are performed on the machining rate and surface corrosion factor. Analysis of the electrochemical machining process with PROMETHEE-II shows that 7 V, 60% duty cycle, and 30 g/L electrolyte concentration are estimated to be the best combination for a higher machining rate and a lower surface corrosion factor. KEY WORDS: Alumina, Machining rate, Nyquist plot, Electrochemical machining, PROMETHEE-II Bull. Chem. Soc. Ethiop. 2024, 38(4), 1163-1175. DOI: https://dx.doi.org/10.4314/bcse.v38i4.27

Analisis Metode Anodizing Aluminium dengan Variasi Kuat Arus sebagai Material Velg Kendaraan

Aluminum Alloy 6061 is widely used in various engineering applications, including automotive vehicle wheels. The selection of aluminum alloy wheels involves aspects such as corrosion resistance. To enhance corrosion resistance, there are several methods, one of which is anodizing. Anodizing is a process that involves an electrolytic coating process that transforms the surface of aluminum into aluminum oxide (Al2O3), which the main process of aluminum anodizing requires a solution of sulfuric acid, chromic acid, or a mixture of sulfuric acid and oxalic acid. The sulfuric acid used must be concentrated acid, and acid is an oxidizing substance. The thickness of the oxide is approximately twice the thickness of the lost aluminum. The purpose of this research is to determine the characteristic such as surface roughness values, corrosion rates, and changes in morphology in Aluminum 6061 after undergoing anodizing. In this study, various current strengths were used, namely 0.75 Amperes, 1.5 Amperes, 2.25 Amperes, and 3 Amperes. The highest surface roughness value was obtained at 0.447 μm in the third specimen of the 0.75 Ampere variation, while the lowest was 0.075 μm in the first specimen of the 3 Ampere variation. The highest corrosion rate was observed in the 0.75 Ampere variation, with a rate of 17.724004 mpy, and the lowest was 0.0731653 mpy in the 3 Ampere variation. SEM results show that, in general, Aluminum 6061 tends to have a bright gray color, which is a surface that has been coated by cathode.

Modal Analysis of Automobile Wheels based on Lightweight Technology

Compared with traditional wheels, magnesium alloy wheels have the advantages of higher strength, toughness, lighter weight, beautiful appearance and so on. This paper takes magnesium alloy wheel as the research object, and uses Pro/e and ANSYS to help complete a lot of work such as 3D model construction and finite element analysis and calculation, to ensure that the magnesium alloy wheel can meet its strength requirements while being lightweight. The strength analysis and modal analysis of the designed wheel model are carried out under various working conditions. According to the analysis results, the first design model is further simplified, and then the calculation and analysis are repeated many times. It is found that the new model meets the mechanical properties requirements under multi-working conditions, ensures that the requirements of lightweight design are met, and provides relevant theories and methods for wheel design and structural optimization of other materials.

Planning Mechanical Behavior of A356 Alloy Wheels by Using Distinct Heat Treatments

The aim of this investigation concerns evaluating the mechanical strength and microhardness values of A356 alloy samples in distinctive heat treatments, including those commonly applied to automotive wheels. It is recognized that A356 and Al-Si-based alloys exhibit considerable versatility across numerous industrial applications. The mechanical behavior obtained is intimately associated with different operational parameters (e.g., cooling rates, solution treatment, quenching, and artificial aging). In this study, a group of samples are quenched at 30, 60 and 80 °C. Another set is quenched and subsequently aged at three different temperatures, i.e., 180, 200, and 220 °C for 5 h, and mechanical responses are compared. Microstructural characterization, X-ray diffraction (XRD) analysis, tensile testing, and microhardness measurements are carried out. Using the Rietveld data and based on the modified Williamson–Hall method, the microstrains, crystallite size, and dislocation densities are calculated. Based on this, the resulting mechanical strengths from distinctive quenching and aging are understood. It was found that there exists a “quasi-optimal range” of operational parameters involving different A356 alloy treatments, which vary depending on the manufacturing route. Considering A356 alloy wheels, the planning of the powder coat treatment before or after T6 treating provides better mechanical properties and ductility.

Effect of copper addition on mechanical properties and microstructures of LM25 cast alloys

The use of aluminum alloys in automobiles is expanding, and the potential for additional increases is significant. Further growth will be determined by improvements in material qualities for existing applications or the discovery of new applications. Alloy A-356 (LM25) is commonly employed for high-quality alloy wheel rims in various motor vehicles, constituting 40% of global car usage. This study introduces 0.2% Cu into the Al–Si–Mg alloy system to enhance the mechanical properties. The alloy blend is cast into a metal mold, subjected to a 4-h cure at 540 °C, quenched with water, and precipitation hardened for 12 h at 1800 °C. Optical and scanning electron microscopes are utilized to analyze the alkali microstructure. The mechanical properties of alloyed and unalloyed castings, including hardness and tensile test results, are examined in untreated and heat-treated states. Fracture surfaces of tensile specimens are scrutinized. Intermetallic compounds formed during solidification are studied using scanning electron microscopy and x-ray diffraction analysis. The tensile strength under unalloyed (LM25) and alloyed (LM25 + 0.2 wt. % Cu) conditions before and after heat treatment [(72, 165.4 and 88.3, 237.1) and (78, 179.6 and 98, 252.9, respectively)] shows a significant increase.

Equilibrium between Environmental and Economic Objectives: An Activity-Based Costing Approach Application for Carbon Emissions Management in the Aluminum Alloy Wheel Industry

In the face of the increasingly dire threat of global climate change, reducing carbon emissions has become an urgent priority for governments and corporations worldwide. The aluminum alloy wheel manufacturing industry bears an even heavier burden for emission mitigation due to its high production volume, complex processes, and proportionally higher carbon footprint. With impending carbon taxes and trading policies looming, the industry urgently needs to strike a balance between maximizing profits and minimizing carbon emissions. Leveraging real-world industry data, this research develops four green Activity-Based Costing (ABC) models and utilizes optimization software to compare the following scenarios: non-continuous carbon tax, carbon tax with trading, tiered tax with exemptions, and exemptions combined with trading. Results demonstrate that integrating carbon trading and targeted tax reductions can improve corporate financial positions without severely compromising environmental goals. Although identifying optimal balance points remains a highly complex process, this study equips enterprises and policymakers with quantitative tools to navigate fluctuating carbon regulatory environments. As national policies progress, more multifaceted dynamic carbon tax models will likely provide more profound insights for sustainable development.

Solidification and Strength Behavior of A356 Al Alloy Wheels

Solidification and Strength Behavior of A356 Al Alloy Wheels

On optimization of Spin-Forming Process Parameters for Magnesium Alloy Wheel Hub Based on Gray Relational Analysis.

To study the influencing factors of process parameters on the wall thickness deviation and internal warpage deviation of the workpiece in magnesium alloy wheel hub spin molding, a two-pass heterogeneous spin molding model is proposed. To ensure the accuracy of the simulation results, the stress-strain data of AZ31 magnesium alloy at different temperatures and different strain rates were obtained through tests. Wall thickness deviation and internal warp deviation after molding were used as evaluation indexes of workpiece molding quality. ABAQUS software facilitated the numerical simulation and analysis of the magnesium alloy wheel hub spinning process. Gray relational degree analysis optimized the first-pass process parameters, elucidating the impact of the axial offset, the thinning ratio, and the feed ratio on forming quality. The application of optimized parameters in the hub spinning simulation resulted in a substantial 28.84% reduction in wall thickness deviation and a 4.88% reduction in inner diameter deviation. This study underscores the efficacy of employing Gray Relational Analysis for comprehensive parameter optimization, ensuring wheel hub quality. Moreover, it provides a theoretical foundation for enterprises to expedite research and development cycles and minimize associated costs.

Finite Element Analysis of Aluminum Based R22 Car Wheel Design Modification

The wheels are one of the main parts of the vehicle. To make car wheels, manufacturers must complete several stages. Especially in the design of the wheels. This study aims to determine the comparative value of three different types of wheels with the same material using aluminum type 6061-T6 (SS). We will test the three-wheel models, namely model 1, model 2, and model 3, with a force of 3000 N and a pressure of 800 N to compare their performance. This test uses Solidworks 2019 software with the finite electronic analysis (FEA) method. The results obtained are the value of Von Misses stress, resulting displacement, equivalent strain and its deformation, and factor of safety. The dimensions of the wheels are 22 inches. The results of the best Model 3 alloy wheel research indicate that the design process is easier. These wheels have a Von Misses stress value of 11.02 MPa with a resulting displacement value of 0.021 mm, an equivalent strain of 0.000096, a safety factor of 25, and a deformation value of 1. Based on these results, model 3 alloy wheels are safe.

DEVELOPMENT AND PERFORMANCE OPTIMIZATION OF ECM PARAMETERS ON SCRAPPED ALLOY WHEEL METAL MATRIX COMPOSITES

Electrochemical machining (ECM) is a nontraditional technique for application of metal matrix composites in aerospace, military, and other engineering uses. ECM factors such as voltage, electrolyte concentration, duty cycle, and electrolyte temperature are varied to evaluate the machining rate. radial overcut, and delamination factor on scrapped alloy wheel MMC. The entropy-based weight assessment method coupled with gray relational analysis is used to perform multi objective optimization. As per the entropy method the weight assigned to MR, ROC and DF is 0.3105, 0.3432 and 0.3463, respectively. The gray relational grade predicts that 8 V, 20 g/lit, 50% and 40°C is the optimal setting for higher machining rate and lower radial overcut and delamination factor.

Optimization of Process Parameters for Machining of Steel Molds used for Aluminum Casting in Wheel Industry

The wheel industry, employing low-pressure casting techniques for producing lightweight alloy wheels, operates within a highly competitive manufacturing environment with significant production volumes. To fabricate essential mold core components for the aluminum wheel casting process, hot work tool steel alloys are selected for their exceptional durability and resistance to wear, fatigue, distortion, and high-temperature plastic deformation. Efficient machining operations for these steel molds require identifying optimal parameter combinations to minimize tool wear, surface roughness, and energy consumption while maximizing material removal rates. This study focuses on determining such parameters, utilizing DIN 1.2367 steel, to enhance manufacturing efficiency and meet industry requirements. The effects of machining parameters such as cutting speed, depth of cut, and number of inserts were investigated using the design of experiments. Depth of cut was determined as the most influential factor on tool wear, revealing the optimum parameter as 0.4 mm, followed by cutting speed. Notably, the number of inserts exhibits minimal direct impact but interacts significantly with the depth of cut, influencing wear patterns. This research contributes to sustainable machining practices by enhancing mold core manufacturing efficiency, prolonging tool life, and reducing tool wear. Such advancements are vital for the long-term competitiveness and environmental stewardship of the wheel industry.

Thermal and mechanical behavior of casting copper alloy wheel during wheel and belt continuous casting process

Thermal and mechanical behavior of casting copper alloy wheel during wheel and belt continuous casting process