Run-flat wheel design for passenger cars with finite element method

Abstract

The objective of this research was to design run flat wheels made of aluminum for passenger cars and investigate the stress, strain, and deformation of run flat wheels and their components. The original 17 inch run flat wheels were made of AISI 1020 steel with a weight of 11.3 kg per wheel. The main problems were from the high-level weight as well as the untighten connection, together with noticed gaps taking place between the run flat wheel and the wheel. Therefore, in this study, the AISI 1020 material was changed to the Aluminum 6063 T6 material. The Numerical methodology using the finite element program was also chosen to indicate the comparative differences in the strain values engaged at various locations of both run flat wheels and pan wheels. The results obtained from both approaches using SolidWorks Simulation Program uncovered the consistent results of the experiments with a 10-16% difference in strain values. The complicated 17 inch wheel pan model was next built using reverse engineering and employed as a key reference to design the cross-sectional area of the new run flat wheels made of Aluminum 6063 T6. All these two parts could be connected tightly. The SolidWorks Simulation program was employed to design and examine the strength of both designed aluminum run flat wheels made of aluminum and the wheel pan made of 17 inch aluminum alloy to build passenger cars. The finite element model was furthermore applied for the run flat wheels made of aluminum 6063 T6 and it provided run flat wheels composed of 2 light weighted pieces. The stress, strain, and deformation measured were proven and suggested in the test. The output Von Mises stress did not exceed the Yield stress, within the linear elastic limit and 3 times safety integrity value. The results from the study were that the obtained run flat wheels allowed the driver to continuously drive for a further 50 kilometers at a speed of 50 kilometers per hour without losing control. They allowed possible tire repairing or replacing when situated in a safe and convenient location.