VISVESVARAYA TECHNOLOGICAL

UNIVERSITY
Belgaum, Karnataka-590018

A
PROJECT REPORT (10AU85)
ON
“DESIGN ANALYSIS AND OPTIMIZATION OF WHEEL
RIMS USING CATIA AND ANSYS”
Submitted by
ANUROOP UNNI (1NH14AU004)
MANORANJAN S.K. (1NH13AU058)
MUHAMMAD ZIYAD (1NH13AU039)
VIJAY MAHENDRAN ASHOK (1NH13AU058)
In partial fulfillment of the requirement for the award of the Degree in
Bachelor of Engineering
(Department of Automobile Engineering)
Under the guidance of
Prof. NISHA M KRISHNAN
Assistant Professor
DEPARTMENT OF AUTOMOBILE ENGINEERING
NEW HORIZON COLLEGE OF ENGINEERING
 DEPARTMENT OF AUTOMOBILE ENGINEERING

CERTIFICATE
This is certify that the project report(10AU85)
On
“DESIGN AND FABRICATION OF PNEUMATIC CENTER
STAND”

Is a bonafide work carried out by

ANUROOP UNNI (1NH14AU004)
MANORANJAN S.K. (1NH13AU058)
MUHAMMAD ZIYAD (1NH13AU039)
VIJAY MAHENDRAN ASHOK (1NH13AU058)
In partial fulfillment For award of degree of Bachelor of Engineering in
automobile Engineering of Visvesvaraya Technological University, Belgaum during the
year 2017-2018. It is certified that all corrections/suggestions indicated for internal
assessment has been incorporated in the report deposited in the department library. The
project report has been approved as it satisfies the academic requirements in respect of
project work prescribed for the Bachelor of Engineering degree.

Signature of Internal guide Signature of HOD Signature of Principal

Proff.Nisha M Krishnan Dr. ShridharKurse Dr. Manjunatha

External Viva:
Name of the examiners : Signature with date
 ABSTRACT

The essential of car wheel rim is to provide a firm base on which to fit the tyre.
Its dimensions, shape should be suitable to adequately accommodate the
particular tyre required for the vehicle. In this project a tyre of car wheel rim
belonging to the disc wheel category is considered. The wheel rim is model by
using SOLIDWORKS 2021. By using this software, the risk involved in the
design and manufacturing pro-cess can be easily minimized. So the modelling
of the wheel rim is made by using SOLIDWORKS. Later this wheel rim modal
is imported to ANSYS WORKBENCH 19.2 for analysis work. ANSYS
WORKBENCH 19.2 is the latest software used for simulating and also
calculating the different properties and viewing the results. ANSYS
WORKBENCH 19.2 static structural analysis work is carried out by
considering four different aluminium alloys namely 6061 and 7075, their
relative performances have been observed respectively. In addition to wheel
rim is subjected to modal analysis, part of dynamic analysis is carried out its
performance is observed. In this analysis by observing the results of both static
and dynamic analysis obtained best material is suggested for making an
effective rim structure.
 ACKNOWLEDGEMENTS
We thank the Lord Almighty for showering His blessings on us.

It is indeed a great pleasure to recall the people who have helped us in carrying
out this project. Naming all the people who have helped me in achieving this goal would
be impossible, yet we attempt to thank a selected few who have helped us in diverse
ways.

We wish to an express of our sincere gratitude to Dr. Manjunatha M.E., Ph.D.,

Principal of NHCE, Bangalore, for providing me with facilities to carry out this seminar.

We wish to an express of our sincere gratitude to Dr. Sridhar Kurse M.E., Ph.D.,

Dean-Students Affairs & Head of Department, Mechanical Engg., for his constant
encouragement and cooperation.

We wish to express my sincere gratitude to my teacher and project co-ordinator

Prof. Nisha M Krishnan, Professor in the Department of Automobile Engg., NHCE, for
his valuable suggestions, Guidance, care & attention shown during the planning,
conduction stages of this seminar work.

We express my sincere thanks to all the staff members and non-teaching staff of
Department of Automobile Engg., for the kind cooperation extended by them.

We thank our parents for their support and encouragement throughout the course
of my studies.

ANUROOP UNNI MUHAMMAD ZIYAD

1NH14AU004 1NH13AU039

MANORANJAN S.K. VIJAY MAHENDRAN ASHOK

1NH13AU032 1NH13AU058
 DECLARATION

We ANUROOP UNNI bearing USN:1NH14AU004, MANORANJAN

S.K. bearing USN: 1NH13AU032, MUHAMMAD ZIYAD bearing
USN:1NH13AU039, VIJAY MAHENDRAN ASHOK bearing
USN:1NH13AU058 students of 8th semester, B.E, Automobile Engineering, New
Horizon College of Engineering declare that the project work titled “DESIGN

ANALYSIS
AND OPTIMIZATION OF WHEEL RIMS USING CATIA
AND
ANSYS” has been carried out by us and submitted in partial fulfillment of course
requirement for the award of degree in Bachelor of Engineering in Automobile
Engineering of Visvesvaraya Technological University, Belgaum, during academic year
2017-2018

Date:

Place: Bengaluru

ANUROOP UNNI MUHAMMAD ZIYAD

1NH14AU004 1NH13AU039

MANORANJAN S.K. VIJAY MAHENDRAN ASHOK

1NH13AU032 1NH13AU058
CONTENTS

1. Introduction...................................................................2

2. Literature survey...........................................................8

3. Objectives.....................................................................15

4. Methodology.................................................................17

5. CATIA Modelling.......................................................19

6. Finite Element Method...............................................21

7. ANSYS Resutls............................................................26

a. Case 1..................................................................30

b. Case 2..................................................................32

c. Case 3..................................................................34

8. Final result...................................................................36

9. Conclusion....................................................................37

10. Reference....................................................................38
CHAPTER 1

INTRODUCTION

The wheel is a device the enables efficient movement of an object across a

surface where there is a force pressing, the object to the surface. Early wheels were simple
wooden disks with a hole for the axle . Because of the structure of, wood a horizontal slice of
a trunk is not suitable, as it does not have the structural strength to support weight without
collapsing; rounded pieces of longitudinal boards are required. The spoke wheel was
invented extra newly, and allowed the construction of, lighter, and swifter vehicles. Alloy wheels
are automobile wheels which are made from an alloy, of aluminum or magnesium metals
(or sometimes a mixture of both). Alloy wheels differ from normal steel wheels because of their,
lighter weight, which improves the steering and the speed of the car, however some alloy
wheels are heavier than the equal size steel wheel. Alloy wheels are also better heat
conductors than steel wheels, improving heat dissipation from the brakes, which reduces the
chance of brake failure in more demanding driving conditions. Over the years, achieving
success in mechanical design has been made possible only after years of experience coupled with
rigorous field-testing .

Figure 1: car alloy wheel

Recently the procedures have significantly improved with the emergence of innovative
method on experimental and analytical analysis. Alloy wheels intended for normal use on
passenger cars have to pass three tests before going into production: the dynamic cornering
fatigue test, the dynamic radial fatigue test, and the impact test. Many alloy wheels

Page 2
manufacturing company had done numerous amount of testing of their product but their
method on simulation test on alloy wheel information often kept limited. Historically,
successful designs was arrived after years of experience well aided worth extensive field -
testing. Since the 1970's several innovative methods of testing and experimental stress
measurements have been initiated. In more recent years, the procedures have significantly
improved by the emergence of a variety of experimental and analytical methods for structural
analysis. Durability analysis, that is: fatigue life prediction and reliability methods, for dealing
with various inherent in engineering structures has been used for the study of automotive rims.

In its basic form a wheel is a transfer element between the tire and the vehicle. The main
requirements of an automobile wheel are;
 It should be as light as possible so that unsprung weight is least.
 It should be strong enough to perform the above functions.
 It should be balanced statically as well as dynamically.
 It should be possible to remove or mount the wheel easily.
 It material should not deteriorate with weathering and age. In case, the material is
suspected to corrosion, it must be given suitable protective treatment.

The circle is major part in vehicles which bears mass as well as retains the contact
involving the body and road condition. While designing a wheel assembly the two major
factors had to be careful such as safety and engineering criteria. The major engineering
factors are impact load, vibration and weight of vehicle. Under different load and
stress conditions, the wheel will be subjected to fatigue changes. Aluminum alloy wheels will
give extra strength during service period. The aluminum alloy wheels are made by
using various techniques such as sand casting; gravity die casting, centrifugal , squeeze and
low pressure die casting. Low pressure die casting method is best for producing aluminum
alloy wheel for appreciably falling cavities, porosity, machining time and irregular decrease.
Fatigue is important point of the wheel. The rotary fatigue test is used to detect the
strength and fatigue life of the wheel. In this test we found the wheel rim strength0and
dynamic life of wheel.

Page 3
 The rim is commonly a metal extrusion that is butte into itself to form a hoop, though may
also be a structure of carbon fiber composite, and was historically made of wood. Some
wheels use both an aerodynamic carbon hoop bonded to an aluminum rim on which to mount
predictable bicycle tires. Metallic bicycle rims are now normally made of aluminium alloy.

Tyre:

The wheel's outer covering is called the tire. Typically made out of0rubber, tires offer
cushioned support for the weight of the car, traction control for moving and stopping,
along with a replaceable barrier between rim and roads.

Spokes:

The rim is connected0to the hub by several spokes under tension. One end of each
spoke is threaded for a particular nut, called a nipple, which is used to connect the spoke to the
rim and adjust the tension in the spoke. This is usually at the rim end

Effect of temperature:

Since the volume of gas and the gas itself inside a tire is not adjusted altogether by a
change of temperature, the perfect gas law expresses that the weight of the gas ought to be
specifically relative to the total temperature. Along these lines, if a tire is swelled to 4 bar (400
kPa; 58 psi) at room temperature, 20 °C (68 °F), the weight will increment to 4.4 bar (440 kPa;
64 psi) (+6%) at 40 °C (104 °F) and reduction to 3.6 bar (360 kPa; 52 psi) (- 13%) at −20 °C (−4
°F).

Effect of atmospheric pressure:

The net gaseous tension on the tire is the contrast between the inner swelling weight and
the outer barometrical weight, 1 bar (100 kPa; 15 psi), and most tire weight gages report this
distinction. On the off chance that a tire is swelled to 4 bar (400 kPa; 58 psi) adrift level,
indisputably the inside weight would be 5.15 bar (515 kPa; 74.7 psi) (+24%), and this is the
weight that the tire would need to contain in the event that it were moved to an area with no
barometrical weight, for example, the vacuum of free space. At the most astounding height of

Page 4
business air travel, 12,000 meters (39,000 ft), the climatic weight is lessened to 0.2 bar (20 kPa;
2.9 psi), and that same tire would need to contain 4.95 bar (495 kPa; 71.8 psi) (+20%).

Rim width:

While not entirely a tire parameter, the width of the edge on which any given tire is
mounted has an impact on the size and state of the contact patch, and perhaps the moving
resistance and taking care of attributes. The European Tire and Rim Technical Organization
(ETRTO) distribute a rule of prescribed edge widths for various tire widths.Forces and moments
generated:

Bike tires generate strengths and moments between the wheel rim and the pavement
that can effect bicycle performance, steadiness, and handling.

Vertical force:

The vertical power created by a bike tire is roughly equivalent to the result of expansion
weight and contact patch area. In the truth, is it as a rule marginally more than this in light of the
little yet limited unbending nature of the side walls?

Tires, increments with expansion the vertical solidness, or spring rate, of a bike tire, as
with cruiser and vehicles weight.

Rolling resistance:

Moving resistance is an unpredictable capacity of the materials and development

techniques utilized and the expansion weight, with higher weight (up as far as possible), more
slender packaging layers, more extensive tires (contrasted with smaller tires at the same weight
and of the same material and development), bigger width wheels, and the sky is the limit from
there versatile tread material every one of the having a tendency to have less moving resistance.
Moving resistance coefficients may shift from 0.002 to 0.010, and have been found to diminish
with swelling weight and increment with vertical burden. A learn at the University of Oldenburg
observed that Schwalbe Standard GW HS 159 tires have a Crr of 0.00455 for the ISO size 47-

Page 5
406 (20 in x 1.5 in) and, for the same model tire, a Crr of 0.00336 for the ISO size 37-622
(700c): a size to resistance proportion of about −1.8.

Characteristics:

Lighter wheels can enhance taking care of by decreasing unsprung mass, permitting
suspension to take after the territory all the more nearly and in this manner enhances hold,
however not all compound wheel are lighter than their steel reciprocals. Diminishment in general
vehicle mass can likewise decrease fuel consumption.

Better warmth conduction can disperse heat from the brakes, 0which enhance braking
execution in additionally requesting driving conditions and decreases the shot of diminished
brake execution or even disappointment because of overheating.

Composite wheels are likewise bought for corrective purposes in spite of the fact that the
combinations utilized are not erosion safe. Combinations permit the utilization of alluring
exposed metal completions, yet these require to be fixed with paint or wheel covers. Regardless
of the fact that so ensured the wheels being used will in the long run begin to erode following 3
to 5 years however repair is currently broadly accessible at an expense. The assembling forms
additionally permit complicated, striking outlines. Conversely, steel wheels are generally
squeezed from sheet metal, and afterward welded together (regularly leaving unattractive
knocks) and should be painted to maintain a strategic distance from erosion and/or covered up
with wheel covers/center tops.

Composite wheels are inclined to galvanic consumption, which can bring about the tires
to break air if proper preventive measures are not taken. Additionally, combination wheels are
harder to repair than steel wheels when twisted, however their higher cost normally makes
repairs less expensive than substitution.

Alloy wheels are more costly to deliver than standard steel wheels, and in this manner are
regularly excluded as standard hardware, rather being advertised as discretionary additional
items or as a major aspect of a more costly trim bundle. Be that as it may, composite wheels have
turned out to be impressively more normal since 2000, now being offered on economy and
subcompact autos, contrasted with 10 years before where combination wheels were frequently

Page 6
not processing plant choices on cheap vehicles. Amalgam wheels have for quite some time been
incorporated as standard gear on higher-valued extravagance or games autos, with bigger
measured or "selective" composite wheels being choices. The high cost of composite wheels
makes them alluring to hoodlums; to counter this, automakers and merchants regularly utilize
locking wheel nuts which require an extraordinary key to expel.

Most alloy0wheels are manufactured using casting, but some are forged.
Forged wheels are usually lighter, stronger, but much more expensive than cast wheels.

Page 7
 CHAPTER 2

LITERATURE REVIEW

Shubham V et.al (2019) (1) Wide varieties of materials are used for manufacturing of vehicle rim
and that material is also available in the market which can be used for the wheel rim. Generally used
wheel rim materials are Al alloy, Mg alloy, Steel C1008 and forged steel. Each material has been some
advantages. If testing wheel rim for tire testing equipment having requirement excellent aesthetic
shape with very good heat dissipation without compromise with its costs. But some
material cannot be suitable for off road testing machine. So after the review the author found that so
many researchers research on the wheel rim in case of material weight and life but our work his been
to find out the design and analysis of off road testing wheel rim tire testing rim manufacturing.

Dengfeng Wang et.al (2020) (2) The 16-in. carbon/aluminium constructed wheel's tapered CFRP rim
was designed, optimised, manufactured, and physically tested. First, the three-zone symmetrically
stacked CFRP rim structure was proposed. The built wheel was then subjected to bending, radial
fatigue, and 13 impact analyses.
The fatigue and impact performance of the spoke met requirements, whilst the CFRP rim structure
needed to be reinforced. Therefore, a multi-objective integrated optimization method employing
RBFNN surrogate model coupled with NAGA-II algorithm was proposed to optimise the lay-up
thickness, sequence and angle of the rim structure.

M. Ravichandra et.al (2015) (3) The author observed the findings and compared the stress, strain,
and displacement of the polymeric composite material wheel with the aluminium alloy wheel. For the
same load carrying capacity, a polymeric composite material wheel reduces stress by 35%–40%, strain
by 70%–75%, and displacement by up to 70%.Al alloy is the currently preferred alloy wheel material.
For alloy wheels, he have thought about polymeric composites made of carbon/epoxy, e-glass/epoxy,
and s-glass/epoxy. Based on the findings, it was deduced that carbon/epoxy polymeric composite
material wheels have higher strength and stiffness and are lighter than other polymeric composite
materials and aluminium alloys that were taken into consideration for this inquiry.

Page 8
Chaitanya Sureddi (2018) (4) The research results in the conclusions listed below by the author.
Using the mechanics of materials, the design of the wheel rim used in this study is demonstrated to be
within acceptable limits. When the compared values are in good agreement, the static analysis of the
vehicle wheel rim is validated using analytical methods. When compared to the other designs with
three bolt holes by varied spokes, the five bolt holes with five spokes design produced good results. By
employing poly matrix composites, the weight of the wheel is reduced without increasing stress or
deformation.

K. Venkata Sai Karthik et.al (2016) (5) The author developed a hybrid aluminum-composite wheel
to increase the vibrations of the wheel and increase the ride comfort of an automobile. Model analysis
tests were then conducted to assess the performance of the wheel. A composite aluminum wheel's
deformation and natural frequencies were improved by adding epoxy composite. The natural
frequencies of the hybrid wheel are 1% lower than those of the aluminum wheel, with an equivalent
deformation at the 1 node of 0.120 m (150 Hz) and 0.120 m (151 Hz) correspondingly.

Zhihua Zhu et.al (2010) (6) 7

Page 9
1.Radial Fatigue Analysis of An Alloy Wheel
Authors: J. Janardhan, V. Ravi Kumar, R. LalithaNarayana

Significance of wheel in the vehicles is self-evident. The vehicle (auto) might be towed
without the motor yet in the meantime even that is likewise impractical without the wheels, the
wheels along the tire needs to convey the vehicle load, give padding impact and adapt to the
controlling control.

The Wheel needs to breeze through three sorts of tests before going into generation, they
are cornering weariness test, Radial weakness test and Impact test. In this postulation outspread
weariness examination is done to locate the quantity of cycles at which the wheel is going to
come up short. The 2D of the wheel was made in MDT, the drafting bundle and the same was
sent out to ANSYS, the limited component bundle utilizing IGES interpreter where the 3D
model of the wheel is made. The wheel is fit utilizing SOLID 45 component. A heap of 2500N
was connected on the center range of the haggle weight of 0.207N/mm2 is connected on the
external surface of the edge. The contribute circle openings are obliged all degrees of
opportunity. The examination is conveyed under these imperatives and the outcomes are taken to
carryout for further investigation i.e. weakness module to discover the life of the wheel.
Conclusion: various number of0cycles the analysis has been done.finally we found equivalent
(von-mises) stress we find 9.205x1e6 pa, maximum stress. And the minimum stress is
0.041x1e6 pa. And the deformation is observed as the 0.515x1e-1 mm after running the
fatigue cycles we found that the infinite life at 1.0x109 cycles.

2.Design and weight optimization of an Aluminium alloy

wheel. Author: Sourav Das Submitted in : June 2014

This paper manages the configuration of aluminium compound wheel for vehicles
application which is completed paying extraordinary reference to streamlining of the mass of the
wheel. The Finite Element examination it demonstrates that the advanced mass of the wheel edge
could be lessened to around half when contrasted with the current strong plate sort Al composite
wheel. The FE examination demonstrates that the anxiety created in the upgraded segment is
well beneath the genuine yield anxiety of the Al combination. Conclusion : The wheel plan space

Page 10
is improved keeping in mind the end goal to withstand the current heap of the vehicle with the
element of security with a slightest amount of material and assembling expense and misfortunes.
The five arm structure is the ideal yield of the solver to withstand stresses. Conclusions followed
out amid the advancement and assessing the life of the wheel are as per the following:

The shape of the arm’s cross section is made easier to manufacture and to distribute the
stress induced in the rim.

3.Topology Optimization of Aluminium Alloy Wheel.

Authors: Ch. P. V. Ravi Kumar1, Prof. R. SatyaMeher

Venture incorporates the "Topology Optimization of Cast Aluminum Alloy wheel"

utilizing sway investigation. Since the come up short estimation of plastic strain for standard
Cast Aluminum Alloy Wheel is 4.0%, splits will show up if the Plastic Strain quality is more
prominent than 4%. This examination will anticipate the plastic strain0s incited amid effect
testing. Topology Optimization is done by expanding the thickness of the edge until the plastic
strain quality is underneath 4%. The principle target of the task is to produce a Finite component
model (Hexa & Penta components) utilizing Hyper mesh V10.0 with every one of the properties,
materials, burdens and Boundary conditions as indicated by the customer. Sway examination is
completed utilizing LS-Dyna programming to foresee the plastic strains amid effect test.
Topology Optimization is done by changing the thickness of the edge of the Cast Aluminum
Alloy Wheel until the estimation of the plastic strain is under 4.0%.

The reaction of wheel get together amid the effect test is a basic wonder. In this paper, a
numerical investigation of effect test of the wheel get together was performed utilizing
unequivocal limited component code. 3–D limited component investigation with a sensible
lattice size can dependably assess the reaction. Such results will anticipate the areas, in which the
disappointment may happen amid effect test and enhance the configuration of a wheel with
required mechanical execution. Topology enhancement is done utilizing sway test on Aluminum
composite wheels by differing thickness of the edge. Since the standard come up short estimation
of plastic strain for standard wheel is 4.0%, the thickness of Cast Aluminum Alloy Wheel ought
to be 5.9mm from the outcomes acquired above which will perform palatably.

Page 11
4.Design & Optimization of a Rim Using Finite Element Analysis
Authors: 1,Turaka. Venkateswara Rao , 2,Kandula. Deepthi , 3,K.N.D.Malleswara Rao

In this anticipate we outlined the edge from the current measurements by displaying
programming. There are the models are set up in this anticipate one is genuine one which is
utilized as a part of ordinary/standard vehicles, second one is altered one which is utilized as a
part of most recent vehicles and the last one is the alteration of most recent edge. The three edges
are broke down in Ansys by utilizing 4 unique materials which are Al compound which is a
consistent material and another three are Mg combination, Zn composite and Steel amalgam. The
outcomes were contrasted and the best material and best model was proposed to the organization.

The displaying is done in ace e and the model was spared in the IGES design and
imported into Ansys. In the Ansys programming the examination of 3 models done by changing
the materials. The outcomes were arranged and contrasted in the examination we accompanied
realize that For genuine edge the anxiety qualities are low for Mg amalgam contrasted with all
different composites which are utilized as a part of this anticipate. The al Alloy and Zn amalgam
qualities are closer to the Mg combination so these compounds may use in the deficiency of Mg
composite. For the altered 5 spokes model anxiety qualities are low for Mg compound contrasted
with different amalgams and the outcomes are about same for Al and Zn composite and the
circumstance is proceeds as genuine edge model. In the improved 4 spokes demonstrate
additionally Mg combination performs great contrasted with all other amalgam here likewise the
circumstance is same. Structure this we reason that steel composite not to suggest for an edges
fabricating and the Mg amalgam is useful for a wide range of edges assembling in the second
place Al compound might be utilized. In the thought of models the new improved 4 spokes can
be utilized by changing the ribs thickness shape this edges weight likewise decreases.

5.FatigueAnalysis of Aluminum Alloy Wheel under Radial Load for Passenger

Car Authors:1V.Dharanikumar, 2 S.Mahalingam, 3A.Santhosh kumar

In this paper, weariness life of aluminum amalgam wheel A356 has been investigated
about the spiral stacking and test conditions. The aluminum compound wheel model was planned
by utilizing Solid works 14 programming. At that point 3D model was changed over into IGES
document then imported to ANSYS; we found the aftereffect of static and exhaustion
Page 12
investigation of combination wheel. Likewise we discover the life of wheel, component of
security by utilizing S-N bend.
After culminations of lattice they are apply the weight 2.9653 Mpa at edge, then they are
get the aggregate twisting of wheel most extreme is 0.3833mm and least is 0.131478 at center
point part. The combination wheel of shear anxiety most extreme is 49.195 and least is - 49.241
at center.
The proportional anxiety is 165.97 and 0.058. The life of wheel most extreme 1.7667e6
cycles and the base cycles of wheel is 1.6533e5 at a cross sectional range of the wheel. The
wheel wellbeing greatest at a center point segment on the grounds that the heap is most extreme
acting at an edge. Least load is acting at a center point. The harm of wheel high at a cross
sectional zone of wheel spokes. Limited component examination is completed by reproducing
the test conditions to investigate stress conveyance and weakness life, wellbeing and harm of
combination wheel. The S–N bend approach for anticipating the weakness life of amalgam
wheels by mimicking static investigation with cyclic burdens is found to merge with trial results.
Security elements for exhaustion life and spiral burden are recommended by directing broad
parametric studies.

6.Fatigue Analysis of Aluminum Alloy Wheel under Radial Load

Authors:N. Satyanarayana&Ch.Sambaiah

In this paper a point by point "Exhaustion Analysis of Aluminum Alloy Wheel under
Radial Load". Amid the piece of task a static and weariness investigation of aluminum
combination wheel A356.2 was completed utilizing FEA bundle. The 3 dimensional model of
the wheel was composed utilizing CATIA. At that point the 3-D model was foreign into ANSYS
utilizing the IGES group. The limited component romanticizing of this modular was then
delivered utilizing the 10 hub tetrahedron strong component. The examination was performed in
a static condition. This is compelled in all level of opportunity at the PCD and center part. The
weight is connected on the edge. They are discovering the aggregate disfigurement, elective push
and shear stress by utilizing FEA programming. Furthermore they are discover the life,
wellbeing component and harm of combination wheel by utilizing S-N bend. S-N bend is
contribution for an A.356.2 material. After finishing of cross section we apply weight 2.8653
Mpa at edge The aggregate distortion of wheel most extreme is 0.2833mm and least is 0.031478

Page 13
at center part. The composite wheel of shear anxiety most extreme is 48.195 and least is - 48.241
at center point. The proportional anxiety is 163.97 and 0.038. The life of wheel most extreme
1.7667e6 cycles and the base cycles of wheel is 1.6533e5 at a cross sectional range of wheel. The
wheel security most extreme at a center point part in light of the fact that the heap is greatest
acting at an edge. Least load is acting at a center. The harm of wheel high at cross sectional
region of wheel spokes. Limited component investigation is completed by reenacting the test
conditions to break down anxiety dispersion and exhaustion life, wellbeing and harm of
compound wheel. The S–N bend approach for foreseeing the weakness life of compound wheels
by recreating static examination with cyclic burdens is found to meet with trial results. Security
elements for exhaustion life and outspread burden are recommended by directing broad
parametric studies. The proposed wellbeing elements will be helpful form
manufacturers/fashioners for solid exhaustion life expectation of comparable basic segments
subjected to radial weariness load. By utilizing ANSYS we decide the aggregate miss happening
and burdens created in a compound wheel.

7.Mass Optimization of Automobile Wheel

Rim. Authors’. Chaitanya#1,
B.V.RamanaMurty*2

In this paper an endeavor is made to minimize the heaviness of the wheel by supplanting
the aluminum amalgam with composites. from the limited component estimations it is found that
the mass of the wheel edge can be decreased to half from the current combination wheels. the
examination likewise demonstrates that after the enhancement the anxieties produced from the
wheel edge will be beneath the yield stress. This gave another methodology in the field of
enhancement of traveler auto wheel edge. In this work the displaying is finished by utilizing catia
v5 r20 and investigation is made by utilizing ansys15.0.

The extent of the present examination is worried for the improvement of wheel edge by
performing mass optimization. By changing the materials with Polymer Matrix Composite and
considering the anxiety and weight PEEK with 30% carbon fortified is recommended as best

Page 14
material to supplant the aluminium alloy. By utilizing this material the mass enhancement is
accomplished.

After completion of the meshing, the load of 200KN was applied on the circumference
of the rim. The equivalent stress of wheel maximum was 11.283MPa. The maximum equivalent
stress was at the spokes corner and is minimum at the inner side of the spokes and it was well
below the yield point of the Al alloy hence safe design at 200KN.The total deformation of alloy
wheel was maximum 0.033mm. Maximum deformation was at the circumference of the wheel
and minimum at the bolt portion.

Page 15
CHAPTER 4

METHODOLOGY
1. Geometric Modeling: Here the shapes are studied and are mostly two- or three-

dimensional, although many of its tools and principles can be applied to sets of any

finite dimension. Here the three dimensional model created using 3D software is

subjected to stress conditions, strain displacements.

2. Validation: Using analytical equations, mathematical modeling is developed to verify

the stresses and eigenvalues.

3. Finite element Model: The three Dimensional created using CATIA is imported to FE

software ANSYS and is meshed and that model is called as Finite elemental model.

4. Suitable Boundary Conditions (sensitivity analysis): The meshed model is subjected

to certain boundary conditions and sensitive analysis is done using Ansys. It is done in

Linear and Static Analysis.

5. Results/ Observations.

6. Conclusion.

Page 16
Flow chart of methodology

Page 17
CHAPTER 5

MODELLING

Geometric modelling of the considered wheel using CATIA:

Page 18
CHAPTER 6

FINITE ELEMENT APPROACH

Finite component Method endless supply of segment into Finite number of pieces
(elements), Finite component strategy (FEM) is a numerical procedure for finding inexact
answers for limit esteem issues for halfway differential conditions. It utilizes subdivision of an
entire issue area into more straight forward parts, called limited components, and 0variational
techniques from the analytics of varieties to tackle the issue by minimizing a related mistake
capacity.

INTRODUCTION TO ANSYS

ABOUT ANSYS

Today's business surroundings is overflowing with aggressive difficulties, client

necessities and money related weights. This environment has brought about the need to discover
new techniques for designing more creative items and assembling forms—while minimizing
expenses and time to showcase. For all intents and purposes each industry now perceives that a
key technique for achievement is to consolidate PC based building reproduction right on time in
the improvement procedure, permitting specialists to refine and accept outlines at a phase where
the expense of rolling out improvements is insignificant. ANSYS alludes to this as Simulation
Driven Product Development.

PRE PROCESSOR IN ANSYS

ANSYS creates, markets, and backings building reenactment programming used to

foresee how item outlines will work and how producing procedures will carry on in certifiable
situations. The Company persistently propels reproduction arrangements by, to start with,
creating or gaining the absolute best innovation; then incorporating it into a brought together and
adaptable reenactment stage that permits specialists to effectively perform complex recreations
including the association of numerous material science; and, at long last, giving framework
administrations to oversee recreation procedures and information — all so architects and item

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engineers can invest more energy planning and enhancing items and less time utilizing
programming and hunting down information.

ANSYS – IN STRUCTURAL MECHANICS

Auxiliary mechanics arrangements from ANSYS give the capacity to mimic each basic
part of an item, including direct static examinations that basically gives burdens or distortions,
modular investigation that decides vibration attributes, through to cutting edge transient
nonlinear marvels including dynamic impacts and complex practices.

All clients, from fashioners to cutting edge specialists, can profit by ANSYS auxiliary
mechanics arrangements. The constancy of the outcomes is accomplished through the wide
assortment of material models accessible, the nature of the components library, the heartiness of
the arrangement calculations, and the capacity to demonstrate each item — from single parts to
extremely complex congregations with many segments cooperating through contacts or relative
movements.

ANSYS auxiliary mechanics arrangements likewise offer unparalleled convenience to

help item engineers concentrate on the most critical part of the reproduction procedure
understanding the outcomes and the effect of configuration minor departure from the model.

Advanced Structural Mechanics for All Stages of Product Development:

Auxiliary mechanics arrangements from ANSYS give the capacity to mimic each basic
part of an item, including direct static.

Investigations that essentially gives burdens or disfigurements, modular examination that

decides vibration qualities, through to cutting edge transient nonlinear wonders including
dynamic impacts and complex practices.

All clients, from creators to cutting edge specialists, can profit by ANSYS auxiliary
mechanics arrangements. The constancy of the outcomes is accomplished through the wide
assortment of material models accessible, the nature of the components Library, the heartiness of
the arrangement calculations, and the capacity to demonstrate each item from single parts to

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extremely intricate. Gatherings with many parts collaborating through contacts or relative
movements.

ANSYS basic mechanics arrangements likewise offer unparalleled straightforwardness

ofuseto help item designer's emphasis on the most essential part of the reproduction procedure:
understanding the outcomes and the effect of configuration minor departure from the model.

The ANSYS Advantage

With the unequaled profundity and unparalleled expansiveness of ANSYS building

recreation arrangements, organizations are changing their driving edge plan ideas into
imaginative items and procedures that work. Today, the greater part of the main 100 modern
organizations on the "FORTUNE Global 500" put resources into building recreation as a key
methodology to win in a comprehensively focused environment.

They pick ANSYS as their reproduction accomplice, conveying the world's most far
reaching multiphysics answers for explain their unpredictable designing difficulties. The built
adaptability of arrangements from ANSYS conveys the adaptability clients need, inside an
engineering that is versatile to their preferred procedures and outline frameworks. No big
surprise the world's best organizations swing to ANSYS — with a reputation of 40 years as the
business pioneer — for the best in designing reenactment.

Usually resembling the possibility that associating numerous minor straight lines can
surmised a bigger circle, FEM envelops strategies for interfacing numerous basic component
conditions over numerous little subdomains, named limited components, to estimated a more
perplexing condition over a bigger area.

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