Wheel Rim Research Articles

Predefined Coating Thicknesses for Vehicle Bodies and Wheel Rims

Predefined Coating Thicknesses for Vehicle Bodies and Wheel Rims

Determination of Mechanical Characteristics Plasma Hardened Wheel Steel

A technique for measuring the mechanical properties of plasma-hardened wheel steel with nanoindentation is applied. The purpose of the work is to demonstrate and substantiate the serious differences between the mechanical properties and behavior of materials in nano-volumes from those obtained in traditional macroscopic tests. The features of measuring mechanical properties – hardness, Young’s modulus, elastic recovery – affecting the wear resistance of the surface layers of the material are given. Measurement of the physic mechanical properties of the material makes it possible to evaluate and select the optimal technology for surface modification by surface plasma hardening. It is noticed that the objectivity of determining the hardness, elastic modulus, elastic recovery and flow stress depends on the parameters of the measuring equipment used and strict adherence to the requirements for the imprint depth depending on the thickness of the hardened layer. The studies carried out on wheel steel samples from the rim and from the ridge of a railway wheel subjected to surface plasma hardening under the same conditions. The HV and H of the wheel rim are greater than the corresponding values of the flange, and the young modulus of the wheel flange, on the contrary, is greater for the flange.

Application of Wireless Accelerometer Mounted on Wheel Rim for Parked Car Monitoring.

Damages of different kinds that can be inflicted to a parked car. Among them, loosening of the car wheel bolts is difficult to detect during normal use of the car and is at the same time very dangerous to the health and life of the driver. Moreover, in patents and publications, only little information is presented about electronic sensors available for activation from inside of the car to inform the driver about the mentioned dangerous situation. Thus, the main aim of this work is the proposition and examination of a sensing device using of a wireless accelerometer head to detect loosening of wheel fixing bolts before ride has been started. The proposed sensing device consists of a wireless accelerometer head, an assembly interface and a receiver unit. The assembly interface between the head and the inner part of the rim enables the correct operation of the system. The data processing algorithm developed for the receiver unit enables the proper detection of the unscrewing of bolts. Moreover, the tested algorithm is resistant to the interference signals generated in the accelerometer head by cars and men passing in close distance.

Application of Aluminum and ITS Alloys in the Automotive Industry With Special Emphasis PN Wheel Rims

The use of aluminum in modern cars began in the early 1970s, when under the pressure of the oil crisis, car manufacturers around the world began to reduce the weight of cars in order to achieve the lowest possible fuel consumption. The first applications of larger volumes were radiators, engine blocks and wheels. Meanwhile, in Europe, the average amount of consumed aluminum has continued to increase, reaching an average of 180 kg per car. Aluminum castings, forgings, sheets and extruded parts are used for a large number of car parts, including car bodies, chassis, suspensions, wheels and many others. The use of aluminum is also important for hybrid and battery electric cars. Due to the threat of global warming due to the greenhouse effect, it is very important to reduce the weight of the car by using aluminum, and thus fuel consumption.This paper explains why, now more than ever, vehicle weight reduction is necessary and how aluminum can be used to further improve the sustainability and safety of future generations of cars. Special attention is given to the use of aluminum for car wheels, which represent almost 15% of the average aluminum content in passenger cars.

Measurement of Train Rim Thickness by Machine Learning

The train wheel rim thickness is always manually measured by using handheld devices or in a non-contact way by using laser and image techniques. To reduce the operating costs, this work studied some soft measurement methods with classical machine learning algorithms including neural network (NN), locally weighted linear regression (LWLR), and support vector machine (SVM). By analyzing the correlation between features, it can improve the efficiency of the model. Some approaches were used to optimize the number of hidden layer neurons in NN, parameters in LWLR and SVM. Experiments on real data are conducted, and the results show that the proposed methods can ensure high precision and accuracy, while NN has the highest accuracy.

Observations of the flow experienced by a track cyclist using velodrome, wind tunnel, and potential flow investigations with an instrumented bicycle

A wind tunnel investigation into the effects of yaw on a track bicycle, ridden by an anatomically-accurate pedalling mannequin, is completed and the results are compared with on-track velodrome data. The results show that there is an amplification effect with a minor bicycle geometric yaw creating a major aerodynamic yaw anterior to the bicycle. The magnitude of this aerodynamic yaw angle amplification increases with increasing front wheel rim depth, with a disc wheel producing the most pronounced effect. A second study into the effects of pedalling legs is also completed with the pedalling mannequin. A 2D potential flow model of the leg movement is created and compared to both wind tunnel data with a pedalling mannequin and velodrome data with a cyclist. The results show a reasonable agreement between the model and both the wind tunnel and velodrome data. There is a large variation in the airflow compared to the freestream that is due to the motion of the legs with a minor difference due to the effect of cadence. The data presented here is useful for bicycle design because it demonstrates and quantifies the aerodynamic influence across different parts of the bicycle.

Impact tests of wheels of road vehicles: A comprehensive method for numerical simulation

In the design of automotive wheels, safety is a crucial factor. Homologations, legislation and standards require severe impact tests before a new wheel can be released on the market. Impact tests are usually performed after the wheel has been already designed and the first prototypes have been produced. In case of test failure, significant delays and costs have to be sustained before the wheel can be actually produced. Numerical simulation of wheel impact tests can reduce the risk of test failure and be a valuable tool for the designer to obtain more efficient and light wheels.The paper deals with the full digitalization of the design process of road vehicle wheels. The aim is to reduce as much as possible indoor impact tests to assess wheel rim structural safety. The numerical simulation of impact tests is accomplished by complex finite element models comprising wheel, tyre and test rig structure. Several data can be required for the modelling of the tyre, which are not usually known to the wheel designer. In this paper, a method for the realization of finite element models of different impact tests is presented. By the proposed method, finite element models with a sufficient level of accuracy for the design of the wheel, at a relatively low computational cost, can be obtained by means of a well defined procedure. For tyre characterisation, only simple measurements related to geometrical features, stiffness and frequency response are required.The method is successfully applied to different impact tests such as radial impact tests with flat or V-shaped striker and 13∘ side impact test. For all the considered tests, experimental validations are performed on different wheels, instrumented with strain gauges located at the most stressed areas. The striker accelerations are also reproduced accurately.The method for the numerical simulation of indoor impact tests of road vehicle wheels enables the full digitalisation of design process, with relevant results in terms of ”time to market” reduction and structural safety assessment. The proposed method is useful not only to design wheel rims, but also to design pneumatic tyres.

ARAÇLARDA KABİN İÇİ SESLERİ ETKİLEYEN PARAMETRELERİN TESTLERLE İNCELENMESİ

Vehicles with improved driving comfort are produced in order to be more competitive in the developing automotive sector. One of the parameters that affect driving comfort is the acoustic performance of the vehicle in the cabin. The most explicit sounds that affect the cabin area are road, wind, wheel, trim, and engine sounds. In this study, vibration accumulation on the body of the vehicle has been determined. Accordingly, the vehicle body has been improved with isolation, and sound assessment has been done inside the cabin. It has been determined that the acoustic performance is improved with the isolation improvements in the vehicle. Afterward, the effect of engine types, different body types for the same kind of engine, wheel rim effects, and engine mounts on the interior sound level is examined. In the examination of acoustic performance, it is determined that the articulation index is determinant rather than the sound level. The isolation effect on the vehicle body and the impact of the engine mounts are evaluated by the jury tests.

Design and Methodology for Studying Wheelset Load

The wheelset is one of the most vulnerable parts of a carriage in terms of failures. As a rule, the failure is revealed at the stage of operation and depends not only on the type of material, of which wheel and rails are made, but also on the technology of their manufacture and operation. The main malfunctions of wheelsets, the nature and causes of their appearance are considered from the point of view of train operations. The objective of the study is a brief analysis of wheelsets’ failures, measures to fight them, as well as development of approaches to introduction of new design decisions. As a debatable problem, the authors suggest a thesis that the existing methods for repairing wheels flanges by surfacing are less promising compared to the technical solution proposed by them. The study proposes to increase reliability of wheelsets at the design stage by making minor changes to the wheel design without changing its geometric characteristics and parameters. Taking into account the cause and the places exposed to the greatest defects (wheel flanges and rims), it is proposed that a rim (hoop) made of a material whose hardness is commensurate with hardness of the rail is pressed onto the wheel of the existing structure in places of the most likely occurrence of the defect. The inner surface of the hoop should completely repeat the outer contour of the wheel in contact with the rim, which provides the necessary bond strength. The proposed technical solution will reduce the stressstrain state of the wheel flange, which is the main cause of failure. To assess the suggestion by calculating total stresses arising on the contact surface of the wheel, it is proposed to use the classical theory of strength. The same method is proposed to solve other problems referring to calculation of solutions aimed to increase the life of wheelsets. So, the main idea of the research is to develop goals and objectives and main directions related to making fundamentally new decisions to increase the life cycle of wheelsets during their operation, as well as to develop relevant theoretical principles and a scientific and methodological apparatus.

Development and Characterization of a Compact Device for Measuring the Braking Torque of a Vehicle.

In this article, a new force transducer is designed, developed and built for the measurement of braking forces in the wheel rim of a motor vehicle. The parameters of the transducer design are justified using numerical simulation. In order to install it in the vehicle in a simple and interference-free way, the metal base of the caliper rod is used. It is manufactured and installed in a vehicle in order to obtain the signals of the wheel braking torque, in real time, and at different speeds of circulation, carrying out several tests on the track. Subsequently, data are obtained from calculations of the disc brake system itself. The latter provides instantaneous adherence values between the brake pad and the disc.

FORMATION OF CARBON STEEL STRUCTURE DURING HOT PLASTIC DEFORMATION

Purpose. The main purpose of the work is to determine the peculiarities of the development of recrystallization processes of carbon steel austenite depending on the degree of hot plastic deformation and to develop proposals for improving the structural state of the metal of the railway solid-rolled wheel. Methodology. Two carbon steels of a railway wheel with a minimum and maximum carbon content of 0.55 and 0.65 % and other chemical elements within the grade composition of the steel 60 were used as research material. Samples in the form of cylinders with a diameter of 20 mm and a height of 40 mm were heated in a muffle furnace, exposed for a certain time to equalize the temperature across the cross section of the sample. After that, the samples were subjected to hot compression on Instron type test machine. The temperature interval of hot compression of the samples was 950–1100 ºС, with deformation degrees in height in the range of 10–40%. The strain rate was 10-3–10-2sec-1. A standard etching was used to detect the boundaries of the austenite grains. Structural studies were performed using Epikvant type light microscope at magnifications sufficient to determine the structure of austenite grains. The grain size of austenite was determined by the methods of quantitative metallography. Findings. In the case of hot compression of the railway wheel blank, increasing the concentration of carbon atoms only within the grade composition of the steel is sufficient to increase the average austenite grain size, which confirms the proposals to limit the carbon content in the metal of railway wheels. The formation of a certain degree of austenite structural heterogeneity at the cross section of the rim or hub of the railway wheel is due to a change in the development mechanism of recrystallization processes depending on the deformation value. Under conditions of the same degree of hot plastic deformation, the replacement of one-time compression by fractional one is accompanied by a violation of the conditions of formation of the recrystallization nucleus. As a result of the specified replacement of the scheme of hot plastic deformation we obtain reduction in the austenite grain size. Originality. Based on a study of the development of collective recrystallization processes during the hot compression of carbon steel of the railway wheel, it was determined that the increase in carbon content contributes to the austenite grain increase. After hot compression of the wheel blank, the structural inhomogeneity of austenite that occurs is determined by a change in the mechanism of recrystallization processes development. During deformations above the critical degree, the recrystallization nuclei are formed and successively grow, which leads to the structure refinement. In the case of deformations below the critical value, the growth of austenite grains occurs according to the coalescence mechanism, according to which fragments of boundaries with large disorientation angles consistently disappear. Practical value. For austenite grain refining in massive elements of solid-rolled railway wheel we offer to replace one-time hot compression by fractional one.

Finite Element Analysis of Variable Thickness Disc Wheel Rim for Weight Optimization

Finite Element Analysis of Variable Thickness Disc Wheel Rim for Weight Optimization - written by Nilesh Kumar Popatlal Kankariya , Shailesh S. Pimpale , Dr. Subim N. Khan published on 2020/07/07 download full article with reference data and citations

A novel ergonomic wheelchair reduces bacterial hand contamination

Objective To determine whether bacterial contamination of rider’s hands is less with a novel ergonomic wheelchair (EW) than a standard wheelchair (SW). Experimental design After wheelchair hand rims were disinfected, volunteers wearing nitrile gloves propelled each wheelchair through a standardised “run” in hospital. Post-run cultures were obtained from riders' gloved hands. Bacterial hand counts were compared between runs matched by rider (same rider, different chairs) or time (different riders in each chair, running concurrently), and overall. Setting Minneapolis Veterans Affairs Health Care System (MVAHCS), a large tertiary care facility. Participants Eleven employee volunteers. Intervention EW, as compared with SW. With SW, co-location of hand rims and tyres potentially exposes the user’s hands to tyres, which risks contaminating the user’s hands with ground-source bacteria. Our novel ergonomic wheelchair (EW) separates drive wheel and hand rims, potentially reducing hand contamination. Main outcome measure Bacterial hand counts. Results Post-run bacterial hand counts were over 10-fold lower with the EW than the SW. This was true (i) when the same rider tested both chairs sequentially (n = 8 pairs) (median counts, 40 vs. 1030; p = 0.008), (ii) when different riders tested the two chairs concurrently (n = 9 pairs) (median counts, 40 vs. 660; p = 0.004), and (iii) overall (median counts, 40 [n = 9 runs] vs. 550 [n = 10 runs]; p < 0.001). Conclusion Separation of wheelchair hand rims from tyres significantly reduces bacterial hand contamination. Reduced hand contamination could decrease bacterial infections and dissemination of resistant bacteria, warranting further study. Implications for rehabilitation The novel design of the ergonomic wheelchair, removing the push rim from proximity to the wheelchair tyre, keeps the hands of wheelchair users cleaner. The re-design of the standard manual wheelchair was implemented initially to improve shoulder ergonomics during manual wheelchair propulsion and has the added benefit of reduction in the transfer of bacteria from floors to hands for manual wheelchair users. Since the ergonomic wheelchair has the potential to decrease rates of bacterial infection in manual wheelchair users, further testing is warranted.

Influence of the charge materials on the quality of cast wheel rims made from AK7 alloy

The widespread use of aluminum and alloys based on it in mechanical engineering is determined by high values of specific strength, increased corrosion resistance, as well as the ability to damp vibrations and high energy absorption. These indicators are especially important in the production of cars, as these alloys can reduce product weight and, as a result, the amount of fuel consumed. Reduced weight of cars can reduce harmful emissions into the environment and reduce the pressure on the road surface. Currently, AK7 cast aluminum alloy is the standard alloy for making rims. To obtain an alloy with the necessary properties, it is necessary to take into account the quality of the used charge materials. First of all, this applies to foundry alloys, which are used for alloying and alloy modification. In the study, we studied AlSi10 pig foundry alloy and AlTi5B1 foundry alloy rod.

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

Comparative performance of granular scaling laws for lightweight grouser wheels in sand and lunar simulant

Recently developed granular scaling laws create new opportunities to evaluate particle dynamics between environment and wheel shapes. We investigate the performance of straight grousered (i.e. protrusions added to the wheel rim to better engage the soil) wheels and helical grousered wheels in both silica sand and crushed basalt lunar simulant. Mechanical power draw and velocity of the wheels are compared in both materials for performance assessment. The scaling laws are evaluated for Earth gravity experimentally and reduced gravity through coupled multi-body dynamic and discrete element method (MBD-DEM) simulations. Experimental results show general power prediction error between 20 and 35% for crushed basalt and 15–25% error for silica sand. Velocity prediction error showed high dependence on material, with silica sand error generally between 4 and 10% and crushed basalt varied between 0 and 27%. Simulation results match theoretical predictions more closely with power error under 8% and velocity error under 4% for most speeds. The experimental error was further investigated and shows a new scaling dependency on sinkage (depth which the wheel rim sinks below the terrain surface) thresholds.

Comparative Analysis among Discrete Fourier Transform, K-Means and Artificial Neural Networks Image Processing Techniques Oriented on Quality Control of Assembled Tires

The present paper discusses a comparative application of image processing techniques, i.e., Discrete Fourier Transform, K-Means clustering and Artificial Neural Network, for the detection of defects in the industrial context of assembled tires. The used Artificial Neural Network technique is based on Long Short-Term Memory and Fully Connected neural networks. The investigations focus on the monitoring and quality control of defects, which may appear on the external surface of tires after being assembled. Those defects are caused from tires which are not properly assembled to their respective metallic wheel rim, generating deformations and scrapes which are not desired. The proposed image processing techniques are applied on raw high-resolution images, which are acquired by in-line imaging and optical instruments. All the described techniques, i.e., Discrete Fourier Transform, K-Means clustering and Long Short-Term Memory, were able to determine defected and acceptable external tire surfaces. The proposed research is taken in the context of an industrial project which focuses on the development of automated quality control and monitoring methodologies, within the field of Industry 4.0 facilities. The image processing techniques are thus meant to be adopted into production processes, giving a strong support to the in-line quality control phase.

Three Piece Wheel Rim Weight Reduction by Finite Element Analysis

Three Piece Wheel Rim Weight Reduction by Finite Element Analysis

Study of plasma-hardened wheel steel using nanoindentation

The necessity and possibility of using nanoindentation in studying the physical and mechanical properties of plasma-hardened wheel steel are considered. The goal of the study is demonstration and substantiation of significant differences in the mechanical properties and behavior of the materials in nanoscale tests from those determined in traditional macroscopic tests. The method was implemented using a NanoHardnessTecter nanohardness tester. The electric field formed in the nanoscale hardness tester pressed on the indenter and the diamond tip of the indenter is immersed in the surface layer of the material under study. The characteristics of the surface layer are determined using the developed software. Knowledge of the physicomechanical characteristics of the material (hardness, Young’s modulus, elastic recovery, etc.) which affect the wear resistance of the surface layers, allows one to evaluate and select the optimal surface modification technology using plasma hardening. The credibility of determination depends on the parameters of measuring equipment and compliance with the requirements to the depth of the imprint depending on the thickness of the hardened layer. The studies were carried out on the samples cut from the rim and crest of a railway wheel subjected to surface plasma hardening on a UPNN-170 installation (Russia). It is shown that the hardness (according to VickersHVandH) of the rim is greater, and Young’s modulus, on the contrary, is less than the corresponding characteristics of the crest. Moreover, the wear resistance of hardened structural steel increases after nanostructural friction treatment.