Design and Weight Optimization of Aluminium Alloy Wheel

Abstract- This paper deals with the design of aluminum alloy wheel for automobile application which is carried out paying special reference to optimization of the mass of the wheel. The Finite Element analysis it shows that the optimized mass of the wheel rim could be reduced to around 50 % as compared to the existing solid disc type Al alloy wheel. The FE analysis shows that the stress generated in the optimized component is well below the actual yield stress of the Al alloy. The Fatigue life estimation by finite element analysis, under radial fatigue load condition, is carried out to analyze the stress distribution and resulted displacement in the alloy wheels. S-N curve of the component depicts that the endurance limit is 90 MPa which is well below the yield stress of the material and safe for the application. The FE analysis indicated that even after a fatigue cycle of 10 20, the damage on the wheel is found only 0.2%. Index Terms- AlSi7Mg0.3, wheel rim, Design optimization, stress analysis, weight optimization, fatigue analysis