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Geometrical Optimization of Aluminum Alloy Wheels for High Fatigue and Impact Strength

Shahbazian, Shara | 2023

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  1. Type of Document: M.Sc. Thesis
  2. Language: English
  3. Document No: 56687 (58)
  4. University: Sharif University of Technology, International Campus, Kish Island
  5. Department: Science and Engineering
  6. Advisor(s): Khayyat, Ali Akbar; Pasharavesh, Abdolreza
  7. Abstract:
  8. After the rise of the automotive industry, aluminum wheels have superseded steel counterparts due to their numerous advantages. Foremost among these benefits is their reduced weight, leading to fuel savings and diminished environmental impact. Moreover, aluminum wheels offer enhanced aesthetics and greater strength in comparison to steel alternatives. This thesis focuses on the geometrical optimization of an aluminum wheel model conforming to the standards set by Iran's Department of Standards, aiming to achieve a higher strength-to-weight ratio. While prior research works have mainly focused on weight reduction while maintaining strength within approved standards, this thesis aims at the improvement of the strength and lifetime of the wheel at the same time. Numerical simulation of both impact and cornering fatigue tests are carried out in Abaqus where the stress distribution results are employed to make modifications to the geometrical shape of the wheel. Based on the simulation results, the stresses resulting from the impact test with the Von Mises criterion at the two critical points of the spoke and the hub in the optimized sample have decreased. Moreover, regarding the fatigue behavior, the lifetime of the optimized sample has increased by 98% according to the Goodman criterion. The optimized wheel is then molded and fabricated and the tests are conducted in a real-world laboratory setting to ensure its compatibility with the corresponding standards
  9. Keywords:
  10. Optimization ; Finite Element Analysis ; Vehicle Wheels ; Cornering Fatigue Test ; Aluminum Wheel ; Impact Test ; Impact Resistance

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