Alloy Wheel Research Articles

Numerical prediction of fatigue life of an A356-T6 alloy wheel considering the influence of casting defect and mean stress

A fatigue prediction method considering shrinkage cavity, secondary dendrite arm spacing (SDAS) and mean stress level is presented in the paper. Firstly, the casting process of an aluminum alloy wheel is simulated based on ProCAST software. And the data of SDAS and porosity of different parts are predicted based on the solidification process. Then the data mapping algorithm between tetrahedral mesh elements is developed to realize the unidirectional transformation of microcosmic data from a cast model to a static mechanical model. And the radial loading mechanical analysis model of a wheel containing microcosmic information is further established. According to the specific mechanical and fatigue parameters of each node, the fatigue life prediction model is established by Fesafe software. Based on the self-developed Transfer Couple Data (TCD) software, the integrated coupling method of the three software prediction models is realized, and the method is further used to realize a precise prediction of the radial fatigue life of a wheel considering effects of shrinkage cavity, SDAS and mean stress. Compared with the experimental results, after considering the microcosmic influence, the predicted position of the minimum life is unchanged, and the predicted life value is more accurate after considering the microcosmic influence. The proposed method lays a solid foundation of the optimization design and lightweight design of aluminum alloy wheels.

Effects of ageing on low-cycle fatigue (LCF) properties of AZ80 magnesium alloy wheel hub

A hollow billet Expanding-Reducing Extrusion (ERE) wheel hub forming process was carried out with AZ80 magnesium alloy. The effects of ageing on Low-cycle fatigue (LCF) properties were investigated, and the microstructure was characterized with scanning electronic microscopy (SEM). The LCF testing results exhibited that the stress amplitude increased with increasing ageing time, while the plastic strain decreased with increasing ageing time. Cyclic softening followed by hardening was observed for 0 h and 16 h aged samples; however, there was no obvious cyclic softening or hardening for 36 h aged sample. The tension-compression asymmetry were not obvious due to the low strain, precipitation and the non typical basal texture. Fracture observations indicated that the fatigue cracks were initiated on the surface, and the crack propagation area decreased with increasing ageing time. Thus, it can be concluded that ageing has strong effects on the fatigue life for the studied magnesium alloy.

Numerical Simulation of Latent Heat of Solidification for Low Pressure Casting of Aluminum Alloy Wheels

In this paper, aiming at focusses on many problems existing in the mathematical model of temperature change in the low-pressure casting solidification process of aluminum alloy wheel hub, there is a big gap between the simulation and the actual temperature change, which affects the research on the solidification defects of the wheel hub. In order to study the solidification behavior of aluminum alloy hub in low-pressure casting process, the mathematical model describing the temperature change in the process of casting solidification is established by using different solidification latent heat methods. through finite element simulation and experiment, the temperature change in the process of aluminum alloy (A356) solidification is obtained to compare the difference between the temperature change described by different mathematical models, simulation and experiment. The results show that the temperature numerical model of "the temperature compensation heat capacity method" proposed in this paper is most consistent with the simulation temperature change during the solidification process of the aluminum alloy wheel in the simulation mold, which lays a good theoretical foundation for the study of the low-pressure casting process of the aluminum alloy wheel hub.

Analisis Manajemen Organisasi dan Sumber Daya Manusia (Studi Kasus pada Industri Velg Mobil)

Due to the importance of organizational management and human resources (HR) in the company, this study intends to analyze several aspects related to these two things, such as internal and external conditions of the company, existing business strategies, existing organizational structures, and job descriptions in a position. This research chooses one of the long-standing car alloy wheels industry. By conducting SWOT method, observations and interviews, there are some conclusions about the company's existing conditions and the formulation of new business strategies. The recommendations proposed in this study include to optimize opportunities and to strengthen the internal factors of the company (SO strategy), to design a new organizational structure with the addition of several specific positions, and to design HR strategies to be more competent.

Investigating the Mechanical and Microstructural properties of Aluminium based Alloy Wheel Rims after TIG Welding

The quantity of motor vehicles is increasing in our country as also seen in the world. From the fact that usage of minimum 4 wheels per a motor vehicle, increasing traffic accidents results by deformation of vehicles parts especially wheels in economic considerations. As nowadays road conditions taken into account, the accidents damage especially tires, wheels and deform the rims and even can break them. The rims that produced from aluminium based alloys that presents a nice view and also maintains satisfactory mechanical values versus their weights are deformed by customary road conditions are being unbended and even welded by automobile wheel repairers. Because of the aluminium based alloy made motor vehicles wheel rims are too expensive to buy, they may be repaired. Hence; the aim of this research will be helpfull in determining and questioning whether qualification of their strength properties is adequate or not after the rims have been repaired by welding. For this purpose in this study; mechanical and microstructural properties of weld metal of motor vehicles Aluminium based alloy wheel rims were investigated after TIG welding. The microstructures of base and weld metals are determined to be in close structure and microvickers hardness test results are also in near values between each other regionally. Aluminium bases alloy wheel rims can be repaired by TIG welding after deformation of them.

Characterization Study and Fabrication of Aluminium Bronze Wheel Rim for Automobile

The wheel rim plays a vital role for good running of the vehicle and the most important safety components from a structural point of view. It must be made with adequate strength and lighter in weight to reduce the unsprung mass of the vehicle and plays a major role in vehicle dynamics. The present study deals with the comparison of structural analysis of aluminium bronze alloy wheel rim with three different compositions to enhance corrosion and fatigue resistance. The design of the wheel rim was created by CATIA V5 and structural behaviour was analysed by ANSYS workbench. The results showed that combination of 90% Al alloy and 10% CuSn) gives adequate strength compared to other combinations of aluminium and bronze. The fabrication of the rim was done by casting methods. Various test like impact, shear, hardness and ultimate tensile tests were conducted to know the mechanical strength of the rim. Salt spray corrosion test was carried out to know the corrosion behaviour of the rim and the results show that no corrosion was found up-to 240 hours

Utilization of waste spent alumina catalyst and agro-waste rice husk ash as reinforcement materials with scrap aluminium alloy wheel matrix

In this study, an attempt was made to utilize waste products from industries to develop composite materials. In the present study, car scrap aluminium alloy wheels (SAAWs) was used as matrix material. Waste rice husk ash (RHA) was collected from a rice mill to utilize as a primary reinforcement material. Spent alumina catalyst (SAC) waste was used as a secondary reinforcement material. SAC was collected from the oil refinery industry. These wastes produced lots of soil and air pollution. However, by utilizing these wastes, some environment pollutions can be reduced. Car scrap aluminium alloy wheels (SAAWs) based composite material was developed using RHA as primary reinforcement material and SAC as a secondary reinforcement material by stir casting technique followed by squeeze pressure on the universal testing machine (UTM) in mushy zone. Microstructure behaviour shows a uniform distribution of RHA and SAC in a recycled aluminium alloy matrix. Mechanical properties such as hardness, ductility, compressive strength and tensile strength were improved using RHA and SAC as reinforcement material simultaneously in SAAWs matrix material. Thermal expansion behaviour, soil degradation test and corrosion loss were also observed to see the effect of agro-waste RHA and SAC in recycled aluminium alloy.

Advanced Process Simulation of Low Pressure Die Cast A356 Aluminum Automotive Wheels—Part I, Process Characterization

In this work, a plant trial was conducted on an industrial low pressure die casting (LPDC) manufacturing process for the production of aluminum alloy wheels. Various types of data have been acquired, including extensive measurements of temperature at different locations (die, wheel and cooling channels), pressure in cooling channels and size/location of shrinkage porosity in the produced wheels. Moreover, two process conditions were tested in the trial—one was the standard production process condition and the other was designed to generate shrinkage porosity in wheels by altering the die temperature. The large amount of quantitative data acquired in this study helped us to understand the key transport phenomena occurring in the process, which include: (1) a thorough picture of the evolution in temperature at a large number of discrete locations in the die and the casting; (2) the dynamic and complicated heat transfer in the cooling channels both water-on and water-off stages, associated with boiling water heat transfer. This paper (Part I) presents the results and findings obtained from the process characterization. The follow-on paper (Part II) will introduce the developed modeling methodology based on the data produced from this work.

Structural Analysis of Alloy Wheels

The wheel of a car plays a pivotal role to endure the weight applied on it. Usually spokes behave as the supports between the hub and the rim. These spokes must have adequate stiffness and strength to dodge the failure of the wheel. In current days these wheels are comprised of, magnesium alloy, steel and aluminum alloy. To decrease the weight of the wheel, numerous wheel designs are executed and applied for automobiles. As regard to the study of the vehicle stability, it is adequate to perform the structural analysis of the wheels so as to know the equivalent modal considerations.In this work, a Cad model of a typical alloy wheel was designed in SOLIDWORKS software and dynamic analysis is performed on this model. The Stress analysis and Fatigue analysis was done on the chosen design. By observing the results we can see whether the design of wheel and the material is feasible or not under applied load conditions. A comparative study is performed by using results of the analysis of the wheel using different materials. The materials used are: Magnesium Alloy, Stainless Steel and Aluminum Alloy and Titanium Alloy in the end best suitable material for the wheel is determined

Design and comparative strength analysis of wheel rims of a lightweight electric vehicle using Al6063 T6 and Al5083 aluminium alloys

Purpose: Use of aluminium alloys in critical parts of a vehicle is common since they can combine the two important properties of a material those are being strength and lightweight. The aim in this research is to guide to design process of a wheel with taking example of an electric race vehicle implementation. Design/methodology/approach: In this study, the fatigue strengths of wheels produced for a two-person racing electric vehicle (Demobil09) are evaluated by calculating maximum distortion energy criterion (Von Mises) with Finite Element Analysis. Findings: Aluminium alloy wheels are crucial safety related components and are subjected to static and dynamic loads directly. Using FEA results, the weight and equivalent stress of the wheel are both reduced. So, the energy consumption is also decreased. Modal frequencies of the wheel models are determined. Research limitations/implications: In this paper, the materials analysed are AL6063 T6 and Al5083 aluminium alloys. Different materials can be analysed in future works. Practical implications: This paper is focusing on how to reduce the energy consumption of a two-person electric vehicle concentrating on reducing the weight of vehicle wheels. The vehicle is more technological than mass production cars since it is an electric race car which uses a hub motor, the body and chassis are produced using carbon polymer composites and all electronic units are designed and produced. Although its specialities it has homologated safety equipment like seats and safety belts. Originality/value: All boundary conditions must be analysed in details and a strength analysis must be conducted during design of the wheels for different load cases to ensure the strength of a wheel while keeping the weight as low as possible. In this complex process, this paper can give some clues to designers for strengths and weights of the designs since three different wheel forms are evaluated for reducing energy consumption of the vehicle.

A novel approach for the production and characterisation of aluminium–alumina hybrid metal matrix composites

In this study, aluminium–alumina hybrid metal matrix composites were developed using stir–squeeze casting with ultrasonic stirring. Scrap aluminium alloy wheels (SAAWs) were used as the matrix material, with 1, 2, and 3 wt% of nanosized alumina ((Al2O3)n) particles as well as 4, 5.5, and 7 wt% of microsized alumina ((Al2O3)m) particles as reinforcement components. An experimental study was conducted using the Taguchi method with an L9 orthogonal array, and the multiobjective optimisation based on ratio analysis technique was used for optimisation. The effects of different ratios of nanosized and microsized alumina particles as well as ultrasonic parameters, namely amplitude and pulse time, on the microstructure and mechanical properties were evaluated and compared. Pin-on-disc wear tests were conducted in the dry condition under uniform load to determine the influence of nanosized and microsized alumina on the wear behaviour. The results revealed that SAAWs reinforced with 1 wt% of nanosized alumina particles and 5.5 wt% of microsized alumina particles and having an amplitude of 100% and pulse on-time of 180 s exhibited lower porosity and metal loss (wear) as well as higher hardness, tensile strength, and compressive strength than other composites.

Preparation and Mechanical Properties of ZK61-Y Magnesium Alloy Wheel Hub via Liquid Forging—Isothermal Forging Process

A ZK61-Y magnesium (Mg) alloy wheel hub was prepared via liquid forging—isothermal forging process. The effects of Y-element contents on the microstructure and mechanical properties of liquid forging blanks were investigated. The formation order of the second phase was I-phase (Mg3Zn6Y) → W-phase (Mg3Zn3Y2) → Z-phase (Mg12ZnY) with the increase of the Y-element content. Meanwhile, the I-phase and Z-phase formed in the liquid forging process were beneficial to the grain refinement. The numerical simulation of the isothermal forging process was carried out to analyze the effects of forming temperature on the temperature and stress field in the forming parts using the software Deform-3D. Isothermal forging experiments and post heat treatments were conducted. The influence of isothermal forging temperature, heat treatment temperature and preservation time on the microstructure and mechanical properties of the forming parts were also studied. The dynamic recrystallization (DRX), second-phase hardening, and work hardening account for the improvement of properties after the isothermal forging process. The forming part forged at 380 °C displayed the outstanding properties. The elongation, yield strength, and ultimate tensile strength were 18.5%, 150 MPa and 315 MPa, respectively. The samples displayed an increased elongation and decreased strength after heat treatments. The 520 °C—1 h sample possessed the best mechanical properties, the elongation was 25.5%, the yield stress was 125 MPa and the ultimate tensile strength was 282 MPa. This can be ascribed to the recrystallization and the elimination of working hardening. Meanwhile, the second phase transformation (I-phase → W-phase → Mg2Y + MgZn2), dissolution, and decomposition can be observed, as well.

Suitable combination of a mean-stress correction method and a stress type for the fatigue analysis of aluminium alloy wheels under radial loading

Finite element analysis (FEA) of the wheel radial fatigue test involves the selection of a combination of a mean-stress correction method and a stress type. This study aims to find the combination(s) of a mean-stress correction method and a stress type suitable for this application. In this work, the Gerber and Goodman mean-stress correction methods are compared when they are used in combination with the absolute maximum principal, signed von Mises and von Mises stresses. The effectiveness of each combination of a mean-stress correction method and a stress type in predicting fatigue failure in the wheel radial fatigue test was evaluated by comparing simulation results obtained by each combination method with experimental results. The results in this work suggest that using the Gerber or Goodman mean-stress correction method with the absolute maximum principal stress is suitable for the fatigue analysis of aluminium alloy wheels under radial loading.

Suitable combination of a mean-stress correction method and a stress type for the fatigue analysis of aluminium alloy wheels under radial loading

Finite element analysis (FEA) of the wheel radial fatigue test involves the selection of a combination of a mean-stress correction method and a stress type. This study aims to find the combination(s) of a mean-stress correction method and a stress type suitable for this application. In this work, the Gerber and Goodman mean-stress correction methods are compared when they are used in combination with the absolute maximum principal, signed von Mises and von Mises stresses. The effectiveness of each combination of a mean-stress correction method and a stress type in predicting fatigue failure in the wheel radial fatigue test was evaluated by comparing simulation results obtained by each combination method with experimental results. The results in this work suggest that using the Gerber or Goodman mean-stress correction method with the absolute maximum principal stress is suitable for the fatigue analysis of aluminium alloy wheels under radial loading.

Mathematical morphology approach to internal defect analysis of A356 aluminum alloy wheel hubs

A356 aluminum alloy is a material widely used in the production of automobile wheels. Internal defects such as gas holes and shrinkage cavities are likely to develop in the process of low pressure casting. X-ray images of the hub are able to provide some information on such defects. This paper proposes a defect extraction method which is built on mathematical morphology. It involves three operations, i.e., the top-hat transform, the top-hat reconstruction transform and the dilation reconstruction. A larger square structuring element and a small threshold are used firstly to obtain all potential defect areas of the hub. A structuring element of a suitable size are applied to different defect areas in subsequent extraction. A new threshold is then decided to get the final defect extraction results. The experimental results show that the above defect extraction method not only works on X-ray hub images, but is robust against the interference caused by noises and hub geometry, and hence can potentially be extensively applied to X-ray detection of hubs.

Mechanical Behavior of Aluminum Metal Matrix Composite for Wheel Hub Application

Now the days of light weight application in a industry. In light weight application the material also strength of the material also important once. The material behavior load character station and application area also important once. The most of the material not suitable for the application. In this work the aluminum MMC material has been chosen in this work. The main focus of the work is aluminum alloys wheel hub area. The main problem is wear resistance. Generally the alloy wheel hub are with stand in a 50000 KM in motor cycle. Then after they are wear out. When increase the hardness of the material hence the decreasing wear out corresponding wear resistance also improved. In this work the aluminum MMC as taken different level and observed which one material as chosen for the application. Finally we are discussed with fracture surface of the materials

Behaviour Analysis of Alloy Wheel Plant

In this paper, Behaviour Analysis of an Alloy Wheel Plant utilizing RPGT under specific conditions has been discussed. An Alloy Wheel Plant is isolated into five sub- systems P, Q, R, S and T for instances of computations. An Alloy Wheel Plant consists of five frame woks for example Gravity Die Machine (P), Cutting Machine (Q), Solutiuonizing Chamber Machine (R), Azing Chamber Machine(S) and Shot Blasting Machine (T). These subsystems are associated in arrangement. On the off chance that any of the sub units comes up short, at that point the Alloy Wheel plant works in diminished state. In the event that at least two sub units fall flat, at that point systems comes up short. Parametric estimations of a system generally rely upon failure / repair rate of individual units. Single server fixes all sub-units. Framework parameters, for example, Availability, MTSF and Number of Server’s Visits utilizing RPGT are determined. Specific cases and behaviour analysis w.r.t different rates are additionally completed pursue by graphs.

Effect of SiC Particulate Reinforcement in A356 / LM25 Alloy Composites and in their Hybrids

LM25/A356 Aluminium Silicon alloy is characterized by high mechanical strength, corrosion resistance, machinabilty and excellent castability. Its prominent usage is found in high performance applications like in the automotive piston, cylinder blocks and heads, valve lifters, alloy wheels, brake pads and also in turbine blades. The prospects in applications of A356 are improved by heat treatment processes. Moreover the production of A356 Aluminium alloy composites renders provision for effectively tailoring the mechanical properties of the material by reinforcing the particulates of different ceramic materials at varying propositions. Although there are wide ranges of ceramic materials that could be potentially reinforced into A356 aluminium alloys, this paper exclusively reviews on SiC particulate reinforced A356 alloy composites and also its hybrid composites fabricated by strir casting method. This paper brings out the researches performed with A356/SiC composites under various experiment conditions to make this aluminium alloy available for other wide applications.

Optimization of Magnesium Alloy Wheel Dynamic Impact Performance

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.

Experimental Investigation of Al-Mg-SiC-Fly Ash Composites for Automotive Alloy Wheel Rims

The conservation of resources is the biggest concern for the past half century. The mankind is heading towards the betterment of living with a key intention to obtain pertaining results with less effort. One such field which has been an extensive outreach for research and innovation is the composite materials. This study focuses on design and development of a new composition of materials which has enhanced mechanical properties than the existing materials. This study is about combining four materials namely aluminium, magnesium, SiC and fly ash in various proportions and to test the obtained specimens. The test specimens are fabricated with aluminium as the metal matrix and other materials (Mg, SiC and fly ash) as reinforcements. Three different combinations are designed by keeping the fly ash, silicon carbide at constant percentage and varying the contents of aluminium and magnesium. The results of the tests are promising and the proposed composition can be a potential reliable replacement material for existing alloy wheels.