“A DESIGN AND ANALYSIS CAR WHEEL USING FINITE ELEMENT METHOD BY ANSYS SOFTWARE”

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http: // www.ijrtsm.com© International Journal of Recent Technology Science & Management 17

IJRTSM

INTERNATIONAL JOURNAL OF RECENT TECHNOLOGY SCIENCE & MANAGEMENT

“

A DESIGN AND ANALYSIS CAR WHEEL USING FINITE ELEMENT METHOD BY ANSYS

SOFTWARE ”

Namit Baraskar

1

, Anil Elisala

2

1_{PG Scholar, Mechanical Engg. Department, B.M. Engg. College, Indore, M.P, India,}

2 _{Associate Professor, Mechanical Engg. Department, B.M. Engg. College, Indore, M.P, India,}

ABSTRACT

The purpose of the car wheel rim provides a firm base on which to fit the tire. Its dimensions, shape should be suitable to

adequately accommodate the particular tire required for the vehicle. In this study a tire of car wheel rim belonging to the disc

wheel category is considered. Design in an important industrial activity which influences the quality of the product. The

wheel rim is designed by using modeling software Inventor. In modeling the time spent in producing the complex 3-D models

and the risk involved in design and manufacturing process can be easily minimized. So the modeling of the wheel rim is made

by using CATIA. Later this CATIA model is imported to ANSYS for analysis work. ANSYS software is the latest used for

simulating the different forces, pressure acting on the component and also for calculating and viewing the results. A solver

mode in ANSYS software calculates the stresses, deflections, bending moments and their relations without manual

interventions, reduces the time compared with the method of mathematical calculations by a human. ANSYS static analysis

work is carried out by considered two different materials namely aluminium and Polyamide and their relative performances

have been observed respectively. In this project by observing the results of static analyses obtained PA-6 is suggested as best

material.

KEYWORDS: Alloy wheel, Principal stress, Deformation & dynamic analysis.

I. I

NTRODUCTION

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concerns. Further, wheels continue to receive a considerable amount of attention as part of industry efforts to reduce weight through material substitution and down gauging.

Although wheels are loaded in a complex manner and are highly stressed in the course of their rolling duty, light weight is one of the prime requirements, hence cast and forged aluminum alloys are essential in the design. Further the current generation automobile have the alloy wheel. This technology up gradation has given multiple choices in respect of material, cross section for rim and arm connecting hub and rim. The newer car is supposed to have lesser weight without compromising the strength. Therefore there is a scope for optimization of wheel design in respect of geometry of car rim, geometry of arm, material etc. The car rim is subjected to static as well as dynamic loading condition. it undergoes bending , twisting, circumferential loading and also impact loading.

Therefore it is justified to have a detailed analysis using the technique like FE for the stresses developed during used. It is proposed to analyze the car rim using FE approach for varied geometry parametric parameter for optimization of its weight.

Fig.1

II. DESIGN

METHODOLOGY

Specifications of Model Wheel rim Steps sketch in Design

Outer diameter = 381 mm

Rim width = 127 mm

Bolt hole diameter = M12 in100mm PCD

Wheel type = Disc wheel

Flange shape = J

Tire type = Radial

Aspect Ratio = 65

Offset = 40 mm

Edge fillet radius = 3 mm and 5 mm

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Fig.3 Dimensional Sketching Fig.4 3D Model

Export 3D model of wheel rim in ANSYS for analysis

Fig.5 3D model import in ANSYS Fig.6 Meshing

Load applied on wheel rim

Each car has various type of load generate. The wheel rim have all weight load faced which is generated by the vehicle. The

weight of Maruti Alto 800 is varying from 1168 kg to 1515 kg. We consider these load are given that.

Load given: Total weight of the vehicle is applied on wheels;

1415 + 350 + 60 = 1825 kg.

1415 = It show the crab weight of vehicle 350 = This value show average weight of person

60 = This value show the extra weight from luggage etc.

Load on each wheel we divided equally: 1825/4 = 456.25 kg.( 4560.25N)

Where 4 is the number of wheels

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Pressure Load: We consider 42 psi of air pressure of without tubeless tire and this value is found from Maruti Suzuki OM

manual. This load is acting on the outer surface of the wheel rim. Therefore

1 psi = 6,894.76 Pascals = 6,894.76 N/m2

42 psi = 42x6, 894.76 N/m2 = 241316.6 N/m2

289579.92 N/m2 = 0.289 N/mm2

III. SIMULATIONS

Fig.7Analyses with load and pressure

Aluminium alloy (A356-T6)

Tensile yield strength of the material = 165 MPa

Tensile ultimate strength of the material = 234 MPa

Young’s modulus = 0.72e5 N/mm2

Density = 2.69 g/cm3

Poisson’s ratio = 0.33

Compressive yield strength = 250 MPa

Elongation = 3.5 % in 50 mm

Polyamide (PA, Nylon 6)

Tensile yield strength of the material = 40 MPa

Tensile ultimate strength of the material 35 to 220 Young’s modulus = 0.16e5 N/mm2

Density = 1.36 g/cm3

Poisson’s ratio = 0.39

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Static analysis result of model with different materials Aluminium alloy (A356-T6)

Fig.8 Displacement Vector Sum of Aluminium alloy Fig.9 Stress intensity of Aluminium alloy

Fig.10 Von mises Stress of Aluminium Alloy

Polyamide (PA 6, Nylon 6)

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Fig.13 Von Mises stress of Polyamide Fig.14 Comparative chart of displacement

Fig.15 Comparative Chart of Von Mises Stress

Fig.16 Comparative weight of wheel rim using different materials

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IV. RESULT

&

DISCUSSION

Summary Table.1

After the analysis we have seen the results of wheel rim model with different material like Aluminium alloy and (PA 6). We find the displacement results Aluminium alloy and (PA 6) is nearly about same 0.028 mm . After the displacement result we find the stress intensity of all materials, the stress intensity of Aluminium alloy 7.85 MPa , and (PA 6) 7.83 are nearly and the Von mises stress results of all materials. We find the Von mises stress of Aluminium alloy 7.04 MPa and (PA 6) 7.12 MPa are nearly and we also seen the weight of all model and we seen the weight of PA 6 model is very low as compare to the other model Aluminium alloy. So it reduces the fuel consumption of vehicle. And cost of PA 6 material is also very low as compare to other materials. Now we suggest after the analysis PA 6 material is best of wheel rim.We have seen the results of displacement, stress intensity, Von mises stress and from model analysis. And we also calculate the weight of each model, and cost of each material in per kg in INR.

V. CONCLUSION

We create 3D model of wheel rim in CATIA software and after that it import to the ANSYS software. And we applied all forces with given boundary conditions and find the all results.

1. In all cases Von-mises stresses of PA 6 is less compare to other materials. So it is safe for designing.

2. Weight of PA 6 model is very low as compare to the other model. So it reduces the fuel consumption of vehicle. Cost of PA 6 model is very low as compare to the other model. Now we suggest after the analysis PA 6 material is best of wheel rim.

VI. FUTURE

SCOPE

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