Design and Analysis of Wheel Rim Using Finite Element Method

International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 10 Issue: 08 | Aug 2023 www.irjet.net p-ISSN: 2395-0072
© 2023, IRJET | Impact Factor value: 8.226 | ISO 9001:2008 Certified Journal | Page 253
Design and Analysis of Wheel Rim Using Finite Element Method
Uma Soliwal 1, Purushottam Sahu2, Ghanshyam Dhanera 3
1Research Scholar BM College of Technology, Indore
2Professor and HOD BM College of Technology, Indore
3Professor BM College of Technology, Indore
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Abstract - we propose that structural steel stands out as
the optimal material choice. This selection leads to a
notable reduction in mass, specifically 4.64 kg per wheel,
resulting in a total weight of the car's spare wheel at 27.84
kg. This reduction not only contributes to the overall weight
reduction of the vehicle but also contributes to decreased
production expenses.
Based on the analysis outcomes, among the six models
considered, wheel design 6 emerges as the superior choice. It
exhibits a lighter weight of 27.192 kg, minimal deformation
(0.00703 mm), a safety factor exceeding 15, and the least
equivalent stress (6.13956 MPa). Subsequently, this model
undergoes a comprehensive analysis employing specialized
tools, which reveals von-Mises stress and total deformation
factors across six distinct structural steel wheel designs.
Following a meticulous comparison of the results, we will
confidently recommend the optimal wheel design.
Key Words: SOLIDWORKS, ANSYS, FEA, Static Analysis,
Fatigue Analysis, Wheel Rim
1. INTRODUCTION
The history of the wheel and rim is a fascinating journey
that spans thousands of years, shaping the way humans
travel, transport goods, and evolve technologically. Here's
a brief overview of the history of the wheel and rim:
1. Early Wheel Concepts (Around 3500 BC): The
earliest evidence of wheeled vehicles dates back
to around 3500 BC in Mesopotamia (modern-day
Iraq). These early wheels were solid wooden
disks, often attached to carts or chariots. They
were initially used for pottery production and
later for transportation of goods.
2. Spoked Wheels (2000-1500 BC): Around 2000 BC,
spoked wheels were invented, likely in the
Caucasus region. Spokes allowed for lighter and
more flexible wheels, which improved overall
efficiency and reduced the stress on the axle.
Spoked wheels spread across civilizations,
including ancient China and Europe.
3. Roman Chariots (4th Century BC - 4th Century
AD): The Romans made significant advancements
in wheel technology, using spoked wheels in their
chariots and military vehicles. This innovation
improved their transportation and military
capabilities.
4. Medieval and Renaissance Innovations (5th-15th
Centuries): During the Middle Ages, wheel
technology evolved slowly. Improvements were
made in terms of axle construction and materials.
In the Renaissance period, Leonardo da Vinci's
sketches and designs included concepts for gear-
driven vehicles with spoked wheels.
5. Industrial Revolution (18th-19th Centuries): The
Industrial Revolution brought significant
advancements in wheel and rim manufacturing.
Iron and steel became common materials for rims
and spokes, making wheels more durable and
capable of handling heavier loads. The
development of railways and steam-powered
locomotives also led to the creation of specialized
train wheels.
6. Pneumatic Tires (Late 19th Century): In the late
19th century, Scottish inventor John Boyd Dunlop
developed the pneumatic tire, which used air-
filled rubber to provide a smoother ride and
better traction. This innovation marked a
significant leap in comfort and performance for
wheeled vehicles.
7. Modern Wheel and Rim Technology (20th
Century - Present): The 20th century brought
further refinements to wheel and rim design,
including alloy wheels made from lightweight
metals like aluminum and magnesium. These
materials enhanced both aesthetics and
performance. Tubeless tires, radial tire
construction, and advanced tire tread designs also
improved safety and handling.
8. Continued Advancements: Today, wheels and
rims continue to evolve with advancements in
materials, aerodynamics, and manufacturing
techniques. The automotive and transportation
industries are exploring technologies like carbon-
fiber composite wheels for improved efficiency
and reduced weight.

The history of the wheel and rim reflects humanity's
continuous pursuit of innovation and improved mobility,
leading to the diverse and sophisticated wheel designs we
see in various vehicles today.
2. METHODOLOGY Finite Element Analysis (FEA) is
a computational method used to analyze complex
structures and systems by dividing them into
smaller, more manageable segments called finite
elements. These elements are connected at
specific points, known as nodes, to represent the
overall behavior of the entire system. FEA is The
Finite Element Method (FEM) has a wide range of
applications across various fields of science and
engineering. It is a versatile numerical technique
that can be used to solve complex problems
involving partial differential equations, and it has
proven to be invaluable in simulating and
analyzing a diverse set of systems. Here are some
notable applications of the Finite Element
Method:
3. Structural Analysis: FEM is widely used for
analyzing the behavior and response of structures
under different loads and conditions. It is used in
civil engineering for designing buildings, bridges,
and other structures, as well as in mechanical
engineering for designing components like beams,
columns, and frames.
4. Heat Transfer and Thermal Analysis: FEM is
employed to study temperature distributions,
heat transfer rates, and thermal stresses in
systems. This is crucial for designing efficient
cooling systems, thermal management of
electronic devices, and analyzing heat flow in
various industrial processes.
5. Fluid Dynamics: FEM is used in computational
fluid dynamics (CFD) to simulate fluid flow,
analyze pressure distributions, and study the
behavior of liquids and gases in pipes, channels,
and other flow domains.
6. Electromagnetic: In electromagnetic analysis,
FEM is used to model and predict the behavior of
electromagnetic fields, such as in antennas,
motors, transformers, and electronic devices.
7. Acoustics and Vibrations: FEM is employed to
analyze the propagation of sound waves and
vibrations in structures, vehicles, and other
systems. This is crucial for noise reduction and
improving the durability and comfort of products.
8. Geomechanics and Geotechnical Engineering:
FEM is used to study the behavior of soils and
rocks under different loading conditions. It's
important for analyzing foundation stability, slope
stability, and excavation processes.
9. Aerospace and Automotive Engineering: FEM
is extensively used in the design and analysis of
aircraft, spacecraft, and vehicles. It helps optimize
structures for weight, strength, and
aerodynamics.
10. Biomechanics: FEM is applied in biomedical
engineering to analyze the mechanical behavior of
biological tissues, bones, joints, and implants. It
aids in designing prosthetics, orthotics, and
medical devices.
11. Material Science: FEM is used to study the
mechanical properties of materials and predict
their behavior under different conditions. This is
crucial for designing new materials and
understanding material failure mechanisms.
12. Manufacturing Processes: FEM is employed to
simulate various manufacturing processes such as
welding, machining, and forming to optimize
process parameters and predict potential defects.
13. Nuclear Engineering: FEM is used to model and
analyze the behavior of nuclear reactors,
including heat transfer, structural integrity, and
safety assessments.
14. Environmental Engineering: FEM can be used to
simulate and analyze environmental processes
such as groundwater flow, pollution dispersion,
and the behavior of contaminants in the
environment.
15. These are just a few examples of the many
applications of the Finite Element Method. Its
ability to handle complex and nonlinear problems
makes it an essential tool in engineering and
scientific research.
Widely employed in engineering, physics, and
other fields to simulate and understand how
structures or systems respond to various
conditions, forces, and loads.
Here's a simplified overview of the FEA process:
1. Model Creation: The first step involves creating a
digital representation of the physical object or
system you want to analyze. This digital model is
often created using specialized software and is
composed of geometric shapes and dimensions.
2. Mesh Generation: The model is divided into a
mesh of finite elements. These elements are
usually triangles or quadrilaterals in two

dimensions and tetrahedra or hexahedra in three
dimensions. The more elements you have, the
more accurate the analysis, but it also increases
computational complexity.
3. Boundary Conditions: Boundary conditions are
defined to simulate the real-world environment in
which the structure operates. These conditions
include fixed points (constraints) and applied
loads or forces.
4. Material Properties: Material properties, such as
elasticity, density, and thermal conductivity, are
assigned to the finite elements to mimic the
behavior of the real material.
5. Solving the Equations: FEA involves solving a set
of mathematical equations derived from the
physical principles governing the behavior of the
system. These equations relate the forces,
displacements, and material properties of the
finite elements.
6. Analysis: The software calculates the
displacements, stresses, strains, and other
relevant variables within each finite element.
These results provide insights into how the
structure responds to the applied loads and
boundary conditions.
7. Interpretation of Results: Engineers and analysts
interpret the results to assess the performance,
safety, and reliability of the system. This may
involve identifying areas of high stress,
deformation, or potential failure points.
8. Optimization and Iteration: Based on the results,
design modifications can be made to improve the
system's performance. The FEA process can be
iterated to refine the design until the desired
outcomes are achieved.
FEA is a powerful tool that allows engineers and
researchers to gain insights into the behavior of complex
systems without having to rely solely on physical testing.
It is used in a wide range of applications, including
structural analysis, thermal analysis, fluid dynamics,
electromagnetic, and more.
3. MODELING AND ANALYSIS
Figure 4.1(a) Wheel Design 1 and (b) Wheel Design 2
Master Model Wheel-Static 1-Stress-Stress1 Name
Master Model Wheel-Static 1-Factor of Safety-Factor of
Safety1 Structural Steel
Total Deformation

Wheel Design 2 Aluminium alloy
VON: von Mises Stress
Resultant Displacement
Figure (a) Wheel Design 1 (b) meshed model
Figure (c) Total Deformation (Design 2)
Figure (c) Equivalent Strain (Design 2)
Figure 5.11 S-N curve of Structural Steel Figure Figure
5.12 Loading Type is Fully Reversed and Analysis Type
is stress Life (Total Life)

In a fatigue study, it's essential to maintain consistent
material properties as those used in static analysis.
Nonetheless, it's imperative to define the fatigue strengths
of materials, which are represented by S-N curves. These
curves encapsulate how a material performs under
repetitive loading, illustrated in Figure 5 as a fully
reversed alternating stress plotted against the number of
cycles on a logarithmic graph. When plotting structural
results on this graph, stress ranges are positioned on the
vertical axis while the cycle count is on the horizontal axis,
often leading to considerable dispersion.
Should the alternating stress surpass the material's
endurance limit, the component's longevity is restricted to
a finite number of cycles. This finite life encompasses two
distinct regions termed low cycle fatigue and high cycle
fatigue. Low cycle fatigue transpires at high stress levels
and relatively few cycles, where the material behavior is
predominantly plastic. Conversely, the high cycle fatigue
region features lower stress levels and elastic material
behavior. Structures exposed to stress levels beneath a
material's endurance limit undergo a substantial number
of load cycles without incurring damage.
5. RESULT
6. CONCLUSION:
Through our investigation, we've discerned that the design
of the wheel rim wields substantial influence over the
overall performance of the wheel. This, in turn, leads to
enhanced handling and a more enjoyable ride due to
reduced weight and an elevated safety factor. The
reduction in weight contributes to improved braking
performance and fuel efficiency, amplifying the benefits
for the vehicle.
A methodology centered around the wheels was employed
to forecast nominal stress and fatigue life. Within the
nominal stress approach, predictions about the wheels'
fatigue life relied upon the S-N curve and the equivalent
stress amplitude of the wheel material.
1. The wheel's mass has been effectively trimmed
from 29.76 kilograms to 25.12 kilograms, all the
while maintaining its physical attributes and
functionality.
2. This weight reduction corresponds to a decrease
of 4.64 kilograms per wheel, culminating in a total
car spare wheel weight of 27.84 kilograms. This
weight reduction carries advantages such as an
overall reduction in vehicle weight and a
consequential reduction in production expenses.
3. The lighter weight contributes to heightened
performance and improved fuel economy. These
findings extend to a range of indirect benefits,
including decreased air pollution due to reduced
fuel consumption, the conservation of natural
resources through diminished crude oil usage,
and more.
4. While the data collection adhered to the same
material and boundary conditions, the diverse
wheel designs significantly influence their
lifespan and safety factor.
Based on analytical statistics, it is evident that among the
six models, wheel design 6 emerges as the optimal choice.
It boasts a lighter weight of 27.192 kilograms, minimal
deformation (0.00703 mm), the highest safety factor
(>15), and a diminished equivalent stress (6.13956 MPa).
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