Design and Analysis of Two-Wheeler Wheel Rim with Different Alloy Materials and Loading Conditions

International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 09 Issue: 04 | Apr 2022 www.irjet.net p-ISSN: 2395-0072
© 2022, IRJET | Impact Factor value: 7.529 | ISO 9001:2008 Certified Journal | Page 112
Design and Analysis of Two-Wheeler Wheel Rim with Different Alloy
Materials and Loading Conditions
L. Sannihith1, J. Kowshik Babu1, B. Rakesh1, M. Sathvik Reddy1, S. Sripathy2
1Research Scholar, Department of Mechanical Engineering, Kakatiya Institute of Technology and Science,
Warangal, India
2Assistant Professor, Department of Mechanical Engineering, Kakatiya Institute of Technology and Science,
Warangal, India
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Abstract - A Wheel is a circular device that is capable of
rotating on its axis, which enables efficient movement of
automobiles. It is one of the highly stressed components in
an automobile that is subjected to loads. At present, alloy
wheels are mostly used because of their lighter weight, high
strength, and better heat dissipation. The Alloy wheel is
designed by using the CATIA V5 software and then it is
imported to Ansys Workbench 2021 R2 to perform static
and dynamic analysis on designed wheel rim with three
different materials namely, Magnesium, Aluminium, and
Titanium alloy. The static and dynamic behavior of the
wheel rim is determined after performing the static and
dynamic analysis. The analysis results of the wheel rim with
different materials were compared in terms Total deflection,
Equivalent (Von-mises) stress, Equivalent elastic strain
under different load conditions and frequencies of modal
analysis, to find out the best possible material for the
designed wheel rim.
Key Words: Alloy wheel, Catia v5, Ansys, Static
Analysis, Dynamic Analysis
1.INTRODUCTION
A wheel is mechanical part of the vehicle
which allows for the easy movement of the load and
bearings present in it take care of the friction it comes
across during rotation. The outer edge of a wheel which
holds on the tire is called the wheel rim. Wheel design is
one of the challenging task in automotive industry where
lot of care must be taken in distributing the loads acting on
the wheel rim by considering loads on the wheel.
Automotive wheels have complicated geometry and must
satisfy manifold design criteria, such as style, weight,
manufacturability, and performance. In addition to being
aesthetic, the wheel design must meet a number of
engineering standards, with good performance and
durability standards and in order to get maximum driving
comfort and road handling capabilities, the wheel must be
as light as possible. Nowadays, one of the most difficult
tasks in the wheel industry is minimizing the wheel
weight. The wheel is designed in such a way that the loads
acting on it should be distributed equally so that the
shocks are avoided and smooth driving is achieved at the
same time the wheel rim should be physically strong
enough to bear the impact loads with less deformation.
2. METHODOLOGY
2.1 Materials:
Alloys possess better corrosion resistance, inexpensive,
higher strength, and better workability than pure metals.
Properties such as machinability, ductility, and brittleness
are governed by the alloy's manufacturing process and
composition. In this study, Aluminium, Magnesium, and
Titanium alloy are considered for the wheel rim material.
Aluminium alloys are alloys with aluminium as the prime
metal. The alloying elements can be copper, tin, zinc,
magnesium etc, based on the application of the material
and its function. The physical and chemical advantages of
aluminium and its alloy are light weight, strong, high
strength to weight ratio, resilient, non-magnetic etc. The
advantages of a product made of it are attractive
aesthetics, easy fabricate, uniform quality, cost effective,
complex shapes, and recyclable. Aluminium is one third
the weight of steel and the manufacturing process has a
great influence on its properties.
Magnesium alloys are alloys with magnesium as prime
material and the alloying elements can be aluminium,
silicon, copper, zinc etc based on the application of the
material to a product. Exceptional machinability, low cost,
high strength to weight ratio, low specific gravity etc. the
advantages of magnesium alloy. The magnesium alloy is
used in automotive, industrial, biomedical, aerospace and
commercial applications. Impurities in the alloy must be
treated properly or can lead to toxic effects during
degradation.
Titanium alloy have very high tensile strength and are
light in weight, corrosion resistance, toughness at higher
temperatures and temperature tolerance. It is heavier
compared to others alloy materials but is stronger which
makes less material usage compared to others.

2.2 Steps Involved:
Flow Chart-1
3. MODELLING
3.1 Catia V5:
CATIA V5 is modelling software. The wheel rim is drawn
in Part design workbench in Catia. The inner and outer
diameter, width of wheel rim is collected and a rough
diagram of Wheel rim is drawn with designed wheel
pattern, then in Catia V5, a cross section is drawn first in
sketcher workbench using basis tools like line, circle,
spine, mirror, trim and then by using tools like pad,
revolve, chamfer and hole a 3D model is generated. The
files are saved as STEP files and used to import into Ansys
Workbench
3.2 Catia Modelling Steps:
1.First in Skecher module, inner and outer diameter is
drawn using Circle command and by using Arc command
arc is drawn connecting 2 circles, then by Using Mirror
Command Other Arc is draw and unnecessary lines are
removed by Trim command as shown in figure 1.
2. The 2D sketch is extruded and made spoke hollow using
Pocket command and single spoke is revolved using
circular pattern as shown in figure 2.
3.Then Wheel cross-section is drawn on spoke and
revolved as shown in figure 3 to generate wheel rim.
4.All the sharp edges are made in smooth curves using
edge fillet.
5. Catia part design file is save as Step file
Fig 1: 2D Sketch
Fig 2: Spokes design
Fig 3: Side View of Wheel rim
Design the aesthetic
look of wheel rim
Modeling [Catia V5]
Considering the
number of loads, forces
Selecting the type of
materials
Static and Dynamic
Analysis
Results and Conclusion

Fig 4: 3D model of Wheel Rim
Fig 5: Different views of Wheel rim
4. ANSYS WORKBENCH:
Ansys is mechanical finite element analysis software
Used to perform different analysis like static structural,
dynamic, fluid, thermal analysis
4.1 Static Structural Analysis:
➢ Steps involved:
I. Engineering data
II. Geometry
III. Model
IV. Meshing
V. Analysis
VI. Results
I. Engineering data:
The Alloy wheel material are selected from the workbench
Library
II. Geometry:
Catia step file is imported into Ansys in geometry and
units are set properly,
III. Meshing:
The finer the mesh, the more accurately the 3d model is
defined
Fig 6: Meshing
IV. Model:
a) Boundary Conditions:
1.The structural model of the rear wheel is taken into
consideration for the accurate analysis result.
2. The motorcycle's net weight is 148 kg.
3.The tyre inner tube filled to a gas filled with pressure
of 0.193 MPa and it is uniformly distributed over the
wheel surface.
4.To ensure the analysis accuracy, the whole weight of the
motorbike and the maximum permitted load was applied
to the rear wheel alone.
Fig 7: Fixed Support

Fig 8: Pressure
Fig 9: Force
b) Load Calculations for Static Analysis:
 Dead weight of bike = 148 kg,
 Other loads = 20 kg,
 Average weight of the one Person = 65 kg.
 Load 0 = weight of bike (148 vehicle +20 extra kg) =
168 kg,
 Load 1 = Bike weight+ one-person average weight=
(148+65) kg =213 kg,
 Load 2 = Bike weight+ one-person average weight=
(148+65x2) kg =278 kg.
 Number of Wheels = 2
 Considering the total load acts on Sigle wheel and
30% of load reduces due to tires and suspension
system. So, resulted net load in newton is given as:
Load 0 = 168 X 9.81 X 0.7 N = 1153.656N
Load 1 = (148+65) X 9.81 X 0.7 N = 1462.671N
Load 2 = (148+65*2) X 9.81 X 0.7 N = 1909.026N
V. Analysis
i) Aluminium Alloy:
a) Total Deformation
b) Equivalent Stress
c) Equivalent Strain

ii) Magnesium Alloy:
iii) Titanium Alloy:

VI. Results:
Table 1: Static Results at Load 0
Aluminiu
m Alloy
Magnesiu
m Alloy
Titanium
Alloy
Displacemen
t (mm)
0.030067 0.047333 0.022154
Equivalent
stress (MPa)
8.9175 8.6724 8.5417
Equivalent
strain
0.0001614
7
0.00024393 0.0001131
7
Aluminiu
m Alloy
Magnesiu
m Alloy
Titanium
Alloy
Displacemen
t (mm)
0.036781 0.057935 0.027123
Equivalent
stress (MPa)
11.069 10.76 10.595
Equivalent
strain
0.0002053
2
0.00031015 0.0001419
3
Aluminium
Alloy
Magnesium
Alloy
Titanium
Alloy
Displacement
(mm)
0.046505 0.073284 0.034318
Equivalent
stress (MPa)
14.191 13.788 13.573
Equivalent
strain
0.00026885 0.00040607 0.0001858
4.2 Modal Analysis:
 A modal analysis, also known as a free vibration
analysis, is used to determine a structure's natural
frequencies and mode shapes.
 It considers the natural frequencies rather than the
structure's response under dynamic loads.
 Before tackling more complex dynamic issues, a modal
analysis is generally the initial step.
 The wheel rim structure resonates at natural
frequencies and these frequencies are obtained by
performing modal analysis on the wheel rim. The
number of modes given is as 6 and fixed support is
provided at the center of hub. Materials applied to rim
are aluminium alloy, magnesium alloy and titanium
alloy for finding the natural frequency.
 The meshing for modal analysis is same as static
structural analysis.
 Different mode shapes and frequencies are obtained
in the modal analysis
Fig 10: Fixed Support in Modal Analysis
Different Mode shapes of Magnesium Alloy
Mode 1 Mode 2
Mode 3 Mode 4
Mode 5
Mode 6

5.RESULTS:
Table 4: Modal Analysis Results
Aluminium
Alloy
Magnesium
Alloy
Titanium
Alloy
Mode 1 (hz) 155.19 153.18 139.65
Mode 2 (hz) 239.57 237.03 216.34
Mode 3 (hz) 240.39 237.9 217.16
Mode 4 (hz) 395 389.23 354.48
Mode 5 (hz) 395.19 389.41 354.64
Mode 6 (hz) 425.85 421.27 384.43
Bar Graph
6.CONCLUSION
The Wheel rim is designed using Catia V5 software.
The finite element analysis of wheel rim is done by using
Ansys workbench 2021 R2. After performing static
structural analysis, various parameters are obtained
namely, Total Deformation, Equivalent Stress, Equivalent
Strain at different loading conditions and different
materials. Modal analysis is carried out with 6 different
modes and 6 mode shapes are obtained for each material.
A comparison is made between different materials in
terms of various parameters. The following are the
findings after static structural and Modal analysis:
a) The designed wheel is safe under different loading
conditions within permissible limits.
b) By comparing static results, Titanium alloy is
considered to be a best material.
c) But in modal analysis, the Titanium alloy dynamic
stability is less compared to both aluminium and
magnesium alloy.
d) Magnesium Alloy is light weight compare to
Aluminium Alloy and Titanium alloy.
e) Equivalent stress of magnesium alloy is lower
than Aluminium Alloy and slightly greater than
Titanium Alloy.
f) By comparing all the results of static structural
and modal analysis results, Magnesium alloy is
best material with less equivalent stress and it is
considered more feasible material for light weight
design with good dynamic stability.
7. REFERENCES
[1] Zhang Guiju & Xiao Caiyuan“Study On Light
Weight Design Of Aluminium Alloy Wheels”,
Australian Journal Of Mechanical Engineering
(Taylor & Francis) ISSN-1448-4846 Published
Online:-29 Jan 2019.
[2] Lei Chen, Shunping Li, Huiqin Chen, David M
Saylor and Shuiguang Tong “Study On The Design
Method Of Equal Strength Rim Based On Stress
And Fatigue Analysis Using Finite Element
Method”,Research Article:- Advances in
Mechanical Engineering (Sage), 2017,Vol9(3) I-II.
[3] Saurabh M Paropate and Sameer J Deshmukh
“MODELLING AND ANALYSIS OF A MOTORCYCLE
WHEEL RIM”, International Journal Of Mechanical
Engineering And Robotics Reasearch, ISSN 2278
– 0149, Issue: - July 2013.
[4] Saran Theja M, Shankar G, Vamsi Krishna M
“Design Analysis of Two-Wheeler Lighter Weight
Alloy Wheel”, International Journal of
Engineering, ISSN-2319-7757 Volume 6, Number
15, November 2013.
[5] Dr Ravinder Kumar, Mohammed Yasir K, Saish S,
Jayant Kumar Pooni, Rishi, I.V.S Yeshwanth,
“DESIGN AND ANALYSIS OF ROTATING WHEEL:
ALLOY WHEELS, ISSN-2349-5162, Issue:Oct
10,2020.
[6] M. Saran Theja , M. Vamsi Krishna,” Structural and
Fatigue Analysis of Two Wheeler Lighter Weight
Alloy Wheel”, IOSR Journal of Mechanical
Engineering ISSN: 2278-1684,p-ISSN: 2320-334X,
Volume 8, Issue :-Jul. - Aug. 2013.
0
100
200
300
400
500
Mode
1
Mode
2
Mode
3
Mode
4
Mode
5
Mode
6
Frequency
(Hz)
No of Modes
Modal Analysis
Aluminium Alloy Magnesium Alloy
Titanium Alloy

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