International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 06 Issue: 05 | May 2019 www.irjet.net p-ISSN: 2395-0072
© 2019, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 5006
Model and Structural Analysis of Two-Wheeler (Motorcycle) Rim using
ANSYS Software
Kuldip Kumar1, Manas Raj Mishra2, Devendra Singh Chauhan3
1M.Tech Scholar, Department of Mechanical Engineering, Rama University, Kanpur (U.P), India
2Asst. Professor, Faculty of Engg. & Technology, Rama University, Kanpur (U.P), India
3Asst. Professor, Department of Mechanical Engineering, Axis College, Kanpur (U.P), India
----------------------------------------------------------------------***---------------------------------------------------------------------
Abstract - Wheels play a vital role of vehicle suspension
which guides the static and dynamic load during vehicle
action. Conventional materials are used to produce the
wheel rim, these are heavy in weight due to this over all
weight of the vehicle is increases. Heavy weight of vehicle
effect the fuel consumption, light weight vehicle delivers
high mileage as compare to high weight vehicle with same
capacity engine. Today the prices of fuels are increasing
day by day so there are huge demands of cheep and fuel
efficient vehicle. Regarding this scenario, reduction in
weight of vehicle is the best step for achievement of cheep
and fuel efficient vehicle. In a motorcycle engine is the
heaviest unit after this wheel of motor cycle is the second
heaviest unit. Wheel rim can be replaced from conventional
materials to composite materials.
Polyetheretherketone (PEEK) is the best composite
material for replacement of conventional materials wheel
rim. PEEK has unique combination of mechanical
properties, resistance to chemicals, wear, fatigue and creep
as well as exceptionally high temperature resistance, up to
260°C (480°F). PEEK is selected due to their superior
mechanical properties, durability and light in weight.
In this paper entire wheel rim design for two wheeler rim
was chosen and analyzed by applying different load and
redesign the wheel rim again to minimize the deformation
and material will be changed from aluminum to PEEK
(polyether ether ketone)
Wheel rim design for two-wheeler is made by using NX 7.5,
and Analysis has been done by ANSYS 14, software to
determine the various stresses, strain and fatigue life of the
wheel rim. The software has helped us really to achieve our
goal. As the whole analysis is done by the means of
software therefore result and observations are trustworthy
and meet with our expectation.
Key Words: Aluminium Alloy, Wheel Rim, PEEK, ANSYS 14,
etc.
1. INTRODUCTION
The wheel is a part that permits efficient movement of an
object across a surface where there is a force pressing the
object to the surface. The spoke wheel rim assembly
contributes the major weight addition in motorcycle after
the engine. To overcome this disadvantage alloy wheels are
invented. While comparing all alloy materials aluminum
alloy is the best of other alloy materials [1].
The design of a motorcycle wheel contains several
complexes and attempt has been made to meet the
requirements of original equipment manufacturers
(OEMs).By using UNIGRAPHICS (NX 7.5),itinvolveswiththe
drawing requirements and design of a motorcycle wheel.
The design in 6 degree of freedom (DOF) for characteristics
and durability has been developed [2].
Automobile industry has a pressureforreductionincostand
to produce fuel efficient vehicles. Composite materials are
the combination of two or more metals or nonmetals is
known as composite materials. Generally composite
materials are lighter and stronger than conventional metals.
Thermoplastic composite materials consist ofthermoplastic
resins as matrix, reinforcement with traditional fibers as
thermo sets matrix. They have shown great promise as
materials for current and future automotive, aerospace and
industrial applications.Composite material wheel isdifferent
from the light alloy wheel [3] and it is developed mainly for
low weight. However, this wheel hasinadequateconsistency
against heat and for best strength. PEEK (polyether ether
ketone) polymer continues to successfully replace steel,
aluminum, bronze, titanium, and other high–performance
materials, because it offers an ideal combination of
mechanical, thermal and aluminum spokes logical
properties, combined with excellent resistance to grease,
oils, acids and all other automotive fluids. PEEK is an ideal
replacement for Aluminum alloy. PEEK is particularlyuseful
in the automobile industry for its weight.
PEEK is three different types:
1. PEEK with 30% Glass fiber,
2. PEEK–90 HMF 20% Carbon fiber
3. PEEK–90 HMF 40% Carbon fiber
Lighter wheels can improve handling by reducing
unstrung mass , allowing suspension to follow the terrain
more closely and thus improve grip, however not all alloy
wheels are lighter than their steel equivalents. Reduction in
overall vehicle mass can also help to reduce fuel
consumption [4].
International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 06 Issue: 05 | May 2019 www.irjet.net p-ISSN: 2395-0072
© 2019, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 5007
2. EXPERIMENTAL
2.1 Steps used in Design
Need or Aim
Synthesis (Mechanism)
Analysis of Forces
Material selection
Design of element
Modification
Detailed drawing
Production
2.2 Design Processer
Vernier calipers used for measurement of Aluminum alloy
wheel rim dimensions. As per the profile dimensions rim is
drawn on the screen of the computer using UNIGRAPHICS
(NX 7.5). After completion of rim drawing the model is
imported in the ANSYS software.
2.3 Aluminium Alloy Wheel Analysis
First of all take the Aluminum alloy material compositioni.e.
LM 13 Material composition of LM13 is Al-Si (BS: LM13)
alloy was used as the matrix material. The alloy contains
11.00 wt.% Si, 1.00wt.% Mg, 1.50 wt.% Ni, 1.00 wt.% Cu,
0.80wt.% Fe, 0.50 wt.% Mn and balance was Al.
Fig-1: 3D Model of Actual Wheel
Table-1: Design Parameters of Aluminum Alloy Wheel
Particulars dimensions
Rim outer diameter 462mm
Rim width 57mm
Hub diameter 144mm
Spokes length 121mm
Angle between two spokes 76.510
2.4 Stress Analysis of Actual wheel
Fig-2: Equivalent Stress in Al-Alloy wheel at 250Kg load =
24.76MPa
Fig-3: Total Deformation in Al-alloy wheel at 250Kg load
=0.03652mm.
Fig-4: Total Deformation in Polyetheretherketone wheel
at 250Kg = 0.074496mm
International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 06 Issue: 05 | May 2019 www.irjet.net p-ISSN: 2395-0072
© 2019, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 5008
Fig-5: Equivalent Stress in Polyetheretherketone wheel at
250Kg =23.152Mpa
Fig-6: Total Deformation of PEEK 30% Glass Fiber Wheel
at 250Kg (2452.50N) = 0.066889mm
Fig-7: Equivalent Stress in PEEK 30% Glass Fiber Wheel at
250Kg(2452.5 N) = 19.901Mpa
Fig-8: Total Deformation of PEEK90HMF20 Wheel
at250Kg (2452.5N) = 0.123558mm
Fig-9: Equivalent Stresses in PEEK 90HMF20 Wheel at
250Kg 2452.5 N = 19.418Mpa
Table-2: Result Analysis at maximum loading
Material Deformation Equivalent Stress
Aluminium
Alloy
Min 0.032467mm 22.008Mpa
Max 0.036525mm 24.76Mpa
PEEK Min 0.066219mm 20.579Mpa
Max 0.074496mm 23.152Mpa
PEEK 30% glass
fiber
Min 0.059457mm 17.689Mpa
Max 0.066889mm 19.901Mpa
PEEK90HMF20 Min 0.109829 mm 17.26MPa
Max 0.123558mm 19.418MPa
International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 06 Issue: 05 | May 2019 www.irjet.net p-ISSN: 2395-0072
© 2019, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 5009
PEEK90HMF40 Min 0..053907mm 16.766MPa
Max 0.060645mm 18.861MPa
2.5 Analysis Data of PEEK Material
Table-3: Mechanical Properties of PEEK
Mechanical property Value Unit
Density 1320 kg m^-3
Coefficient of Thermal
Expansion
0.000046 C^-1
Specific Heat 1470 × 106 J kg^-1 C^-1
Compressive Yield Strength 118 × 106 Pa
Tensile Ultimate Strength 100 × 106 Pa
Reference Temperature 23 C
Young's Modulus 3.6 × 109 Pa
Poisson's Ratio 0.39
Bulk Modulus 6.9608*1010 Pa
Shear Modulus 1.4 × 109 Pa
2.6 Static Analysis of PEEK-Material
(1) Maximum load of 250Kg (2452.5N)
(2) Fix the wheel at the bottom
(3) Apply load at the center
(4) Cylindrical support on outer hub area
(5) Compression only support on rim Circumference
Fig-10: Modified 3D design of alloy wheel
Table-4: Design Parameters of Modified Wheel
Rim outer diameter 462mm
Rim width 57mm
Hub diameter 144mm
Spokes length 121mm
Angle between two spokes 76.510
Spokes thickness 44mm
Fig-11: Total Deformation in Modified wheel of PEEK at
Maximum load of 250Kg (2452.5N) = 0.179253 mm
Fig-12: Equivalent Stress in Modified wheel of PEEK at
Maximum load of 250Kg (2452.5N) = 17.997MPa
International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 06 Issue: 05 | May 2019 www.irjet.net p-ISSN: 2395-0072
© 2019, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 5010
Fig-13: Total Deformation in PEEK30% Glass Fiber
Modified Wheel at Maximum load of 250Kg (2452.5N) =
0.160829mm
Fig-14: Equivalent Stress in PEEK30% Glass Fiber
Modified Wheel at Maximum load of 250Kg (2452.5N) =
16.245MPa
Fig-15: Total Deformation in PEEK90HMF20 Modified
Wheel at Maximum load of 250Kg (2452.5N) =
0.29701mm
Fig-16: Equivalent Stress in PEEK90HMF20 Modified
Wheel at Maximum load of 250Kg (2452.5N) = 15.992MPa
Fig-17: Total Deformation in PEEK90HMF40 Modified
Wheel at Maximum load of250Kg (2452.5N) =
0.145456mm
Table-5: Result Analysis of different Material in Modified
Design
Material Deformation Equivalent
Stress
Aluminium
Alloy
Min 0.078027mm 16.801MPa
Max 0.08778mm 18.901MPa
PEEK Min 0.159336mm 15.997MPa
Max 0.179253mm 17.997MPa
PEEK 30% Min 0. mm 14.44MPa
International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 06 Issue: 05 | May 2019 www.irjet.net p-ISSN: 2395-0072
© 2019, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 5011
glass fiber
Max 0.160829mm 16.245MPa
PEEK90H
MF20
Min 0. mm 14.215MPa
Max 0.29701mm 15.992MPa
PEEK90H
MF40
Min 0. mm 12.621MPa
Max 0.145456mm 14.198MPa
3. RESULT AND DISCUSSION
Table-6: Comparison Analysis Data of Different Material
Material
Analysis Data of
Actual Wheel
Analysis Data of
Modified Wheel
Total
Deformat
ion
Equival
ent
Stress
Total
Deformat
ion
Equival
ent
Stress
Alumin
um
Alloy
Minim
um
0.032467
mm
22.008
MPa
0.078027
mm
16.801
MPa
Maxim
um
0.036525
mm
24.76M
Pa
0.08778
mm
18.901
MPa
PEEK
Minim
um
0.066219
mm
20.579
MPa
0. mm 15.997
MPa
Maxim
um
0.074496
mm 23.152
MPa
0.179253
mm
17.997
MPa
PEEK
With
30%
Glass
Fiber
Minim
um
0.059457
mm
17.689
MPa
0. mm 14.44M
Pa
Maxim
um
0.066899
mm 19.901
MPa
0.160829
mm
16.245
MPa
PEEK -
90HMF
20
Minim
um
0.109829
mm
17.26M
Pa
0. mm 14.44M
Pa
Maxim
um
0.123558
mm
19.418
MPa
0.29701
mm
15.992
MPa
PEEK -
90HMF
40
Minim
um
0.053907
mm
16.766
MPa
0. mm 12.621
MPa
Maxim
um
0.060645
mm
18.861
MPa
0.145456
mm
14.198
MPa
Table-7: Comparison Data of Weight
Material Actual
Wheel
Modified
Wheel
Percentage
Reduction in
Weight
Aluminum Alloy 5.300Kg 4.956Kg 6.5%
PEEK 2.844Kg 2.361Kg 55.45%
PEEK30% Glass
Fiber
3.275Kg 2.719Kg 48.69%
PEEK90HMF20 2.952Kg 2.451Kg 53.75%
PEEK90HMF40 3.125Kg 2.594Kg 51.05%
From the above tables it is clear that modified wheel mass
reduction is maximum 55.45 % in PEEK, after this it is
53.75% in PEEK90HMF20, 51.05% in PEEK90HMF40,
48.69% in PEEK30% Glass Fiber and minimum reduction in
Aluminum Alloy i.e. 6.5%
3. CONCLUSION
From the above tables & discussion it is clear that PEEK is
Best material for the replace of Aluminium material.
Weight of Aluminum Wheel: 5.300 Kg
Cost of Aluminum Wheel: - 15-20K
Weight of Plastic Wheel: - 2.361Kg
Cost of Plastic Wheel: - 8-10K
Author gets the success to achieve the reduction in wheel
rim weight & saving the cost of wheel rim (PEEK) material.
ACKNOWLEDGEMENT
Author wants to say thanks to his guidefortheirsupport and
guidance. Finally author wants to say thanks to all people
who support him directly or indirectly during this work.
REFERENCES
[1] Emmanuel M Adigio, Ebughni O Nangi. Computer Aided
Design and Simulation of Radial Fatigue Test of
Automobile Rim Using ANSYS. IOSR Journal of
Mechanical and Civil Engineering (IOSR-JMCE).
2014;11(1):68−73.
[2] Mohammad Zeeshan, Om Prakash Tiwari & Anil Yadav
(2018) The design and analysisofa motorcyclewheel by
using ansys International Journal of Advance
Engineering and ResearchDevelopmentVolume5,Issue
06, June -2018
[3] Yadav PH, Ramdasi PG. Optimization of Car Rim Using
OptiStruct. IOSR Journal of Environmental Science,
Toxicology and Food Technology (IOSR-JESTFT).
2012;2(3):10−15.
International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 06 Issue: 05 | May 2019 www.irjet.net p-ISSN: 2395-0072
© 2019, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 5012
[4] M. Saran Theja1, M. Vamsi Krishna (2013) Structural
and Fatigue Analysis of Two Wheeler Lighter Weight
Alloy Wheel IOSR Journal of Mechanical and Civil
Engineering (IOSR-JMCE) e-ISSN: 2278-1684,p-ISSN:
2320-334X, Volume 8, Issue 2 (Jul. - Aug. 2013)
[5] Mr. Sasank Shekhar Panda, Mr. Dibya Narayan Behera,
Mr. Satya Narayan Tripathy (2016) “modeling and
structural analysis of alloy wheel using ANSYS”
international journal of engineeringsciences&research
technology.
[6] Machine Design Book by R.S khurmi
[7] K.N.D. Malleswara Rao (2016) “MODEL OPTIMIZATION
AND STRUCTURAL ANALYSIS OF CAR RIM” research
gate

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IRJET- Model and Structural Analysis of Two-Wheeler (Motorcycle) Rim using ANSYS Software

  • 1. International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 06 Issue: 05 | May 2019 www.irjet.net p-ISSN: 2395-0072 © 2019, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 5006 Model and Structural Analysis of Two-Wheeler (Motorcycle) Rim using ANSYS Software Kuldip Kumar1, Manas Raj Mishra2, Devendra Singh Chauhan3 1M.Tech Scholar, Department of Mechanical Engineering, Rama University, Kanpur (U.P), India 2Asst. Professor, Faculty of Engg. & Technology, Rama University, Kanpur (U.P), India 3Asst. Professor, Department of Mechanical Engineering, Axis College, Kanpur (U.P), India ----------------------------------------------------------------------***--------------------------------------------------------------------- Abstract - Wheels play a vital role of vehicle suspension which guides the static and dynamic load during vehicle action. Conventional materials are used to produce the wheel rim, these are heavy in weight due to this over all weight of the vehicle is increases. Heavy weight of vehicle effect the fuel consumption, light weight vehicle delivers high mileage as compare to high weight vehicle with same capacity engine. Today the prices of fuels are increasing day by day so there are huge demands of cheep and fuel efficient vehicle. Regarding this scenario, reduction in weight of vehicle is the best step for achievement of cheep and fuel efficient vehicle. In a motorcycle engine is the heaviest unit after this wheel of motor cycle is the second heaviest unit. Wheel rim can be replaced from conventional materials to composite materials. Polyetheretherketone (PEEK) is the best composite material for replacement of conventional materials wheel rim. PEEK has unique combination of mechanical properties, resistance to chemicals, wear, fatigue and creep as well as exceptionally high temperature resistance, up to 260°C (480°F). PEEK is selected due to their superior mechanical properties, durability and light in weight. In this paper entire wheel rim design for two wheeler rim was chosen and analyzed by applying different load and redesign the wheel rim again to minimize the deformation and material will be changed from aluminum to PEEK (polyether ether ketone) Wheel rim design for two-wheeler is made by using NX 7.5, and Analysis has been done by ANSYS 14, software to determine the various stresses, strain and fatigue life of the wheel rim. The software has helped us really to achieve our goal. As the whole analysis is done by the means of software therefore result and observations are trustworthy and meet with our expectation. Key Words: Aluminium Alloy, Wheel Rim, PEEK, ANSYS 14, etc. 1. INTRODUCTION The wheel is a part that permits efficient movement of an object across a surface where there is a force pressing the object to the surface. The spoke wheel rim assembly contributes the major weight addition in motorcycle after the engine. To overcome this disadvantage alloy wheels are invented. While comparing all alloy materials aluminum alloy is the best of other alloy materials [1]. The design of a motorcycle wheel contains several complexes and attempt has been made to meet the requirements of original equipment manufacturers (OEMs).By using UNIGRAPHICS (NX 7.5),itinvolveswiththe drawing requirements and design of a motorcycle wheel. The design in 6 degree of freedom (DOF) for characteristics and durability has been developed [2]. Automobile industry has a pressureforreductionincostand to produce fuel efficient vehicles. Composite materials are the combination of two or more metals or nonmetals is known as composite materials. Generally composite materials are lighter and stronger than conventional metals. Thermoplastic composite materials consist ofthermoplastic resins as matrix, reinforcement with traditional fibers as thermo sets matrix. They have shown great promise as materials for current and future automotive, aerospace and industrial applications.Composite material wheel isdifferent from the light alloy wheel [3] and it is developed mainly for low weight. However, this wheel hasinadequateconsistency against heat and for best strength. PEEK (polyether ether ketone) polymer continues to successfully replace steel, aluminum, bronze, titanium, and other high–performance materials, because it offers an ideal combination of mechanical, thermal and aluminum spokes logical properties, combined with excellent resistance to grease, oils, acids and all other automotive fluids. PEEK is an ideal replacement for Aluminum alloy. PEEK is particularlyuseful in the automobile industry for its weight. PEEK is three different types: 1. PEEK with 30% Glass fiber, 2. PEEK–90 HMF 20% Carbon fiber 3. PEEK–90 HMF 40% Carbon fiber Lighter wheels can improve handling by reducing unstrung mass , allowing suspension to follow the terrain more closely and thus improve grip, however not all alloy wheels are lighter than their steel equivalents. Reduction in overall vehicle mass can also help to reduce fuel consumption [4].
  • 2. International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 06 Issue: 05 | May 2019 www.irjet.net p-ISSN: 2395-0072 © 2019, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 5007 2. EXPERIMENTAL 2.1 Steps used in Design Need or Aim Synthesis (Mechanism) Analysis of Forces Material selection Design of element Modification Detailed drawing Production 2.2 Design Processer Vernier calipers used for measurement of Aluminum alloy wheel rim dimensions. As per the profile dimensions rim is drawn on the screen of the computer using UNIGRAPHICS (NX 7.5). After completion of rim drawing the model is imported in the ANSYS software. 2.3 Aluminium Alloy Wheel Analysis First of all take the Aluminum alloy material compositioni.e. LM 13 Material composition of LM13 is Al-Si (BS: LM13) alloy was used as the matrix material. The alloy contains 11.00 wt.% Si, 1.00wt.% Mg, 1.50 wt.% Ni, 1.00 wt.% Cu, 0.80wt.% Fe, 0.50 wt.% Mn and balance was Al. Fig-1: 3D Model of Actual Wheel Table-1: Design Parameters of Aluminum Alloy Wheel Particulars dimensions Rim outer diameter 462mm Rim width 57mm Hub diameter 144mm Spokes length 121mm Angle between two spokes 76.510 2.4 Stress Analysis of Actual wheel Fig-2: Equivalent Stress in Al-Alloy wheel at 250Kg load = 24.76MPa Fig-3: Total Deformation in Al-alloy wheel at 250Kg load =0.03652mm. Fig-4: Total Deformation in Polyetheretherketone wheel at 250Kg = 0.074496mm
  • 3. International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 06 Issue: 05 | May 2019 www.irjet.net p-ISSN: 2395-0072 © 2019, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 5008 Fig-5: Equivalent Stress in Polyetheretherketone wheel at 250Kg =23.152Mpa Fig-6: Total Deformation of PEEK 30% Glass Fiber Wheel at 250Kg (2452.50N) = 0.066889mm Fig-7: Equivalent Stress in PEEK 30% Glass Fiber Wheel at 250Kg(2452.5 N) = 19.901Mpa Fig-8: Total Deformation of PEEK90HMF20 Wheel at250Kg (2452.5N) = 0.123558mm Fig-9: Equivalent Stresses in PEEK 90HMF20 Wheel at 250Kg 2452.5 N = 19.418Mpa Table-2: Result Analysis at maximum loading Material Deformation Equivalent Stress Aluminium Alloy Min 0.032467mm 22.008Mpa Max 0.036525mm 24.76Mpa PEEK Min 0.066219mm 20.579Mpa Max 0.074496mm 23.152Mpa PEEK 30% glass fiber Min 0.059457mm 17.689Mpa Max 0.066889mm 19.901Mpa PEEK90HMF20 Min 0.109829 mm 17.26MPa Max 0.123558mm 19.418MPa
  • 4. International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 06 Issue: 05 | May 2019 www.irjet.net p-ISSN: 2395-0072 © 2019, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 5009 PEEK90HMF40 Min 0..053907mm 16.766MPa Max 0.060645mm 18.861MPa 2.5 Analysis Data of PEEK Material Table-3: Mechanical Properties of PEEK Mechanical property Value Unit Density 1320 kg m^-3 Coefficient of Thermal Expansion 0.000046 C^-1 Specific Heat 1470 × 106 J kg^-1 C^-1 Compressive Yield Strength 118 × 106 Pa Tensile Ultimate Strength 100 × 106 Pa Reference Temperature 23 C Young's Modulus 3.6 × 109 Pa Poisson's Ratio 0.39 Bulk Modulus 6.9608*1010 Pa Shear Modulus 1.4 × 109 Pa 2.6 Static Analysis of PEEK-Material (1) Maximum load of 250Kg (2452.5N) (2) Fix the wheel at the bottom (3) Apply load at the center (4) Cylindrical support on outer hub area (5) Compression only support on rim Circumference Fig-10: Modified 3D design of alloy wheel Table-4: Design Parameters of Modified Wheel Rim outer diameter 462mm Rim width 57mm Hub diameter 144mm Spokes length 121mm Angle between two spokes 76.510 Spokes thickness 44mm Fig-11: Total Deformation in Modified wheel of PEEK at Maximum load of 250Kg (2452.5N) = 0.179253 mm Fig-12: Equivalent Stress in Modified wheel of PEEK at Maximum load of 250Kg (2452.5N) = 17.997MPa
  • 5. International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 06 Issue: 05 | May 2019 www.irjet.net p-ISSN: 2395-0072 © 2019, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 5010 Fig-13: Total Deformation in PEEK30% Glass Fiber Modified Wheel at Maximum load of 250Kg (2452.5N) = 0.160829mm Fig-14: Equivalent Stress in PEEK30% Glass Fiber Modified Wheel at Maximum load of 250Kg (2452.5N) = 16.245MPa Fig-15: Total Deformation in PEEK90HMF20 Modified Wheel at Maximum load of 250Kg (2452.5N) = 0.29701mm Fig-16: Equivalent Stress in PEEK90HMF20 Modified Wheel at Maximum load of 250Kg (2452.5N) = 15.992MPa Fig-17: Total Deformation in PEEK90HMF40 Modified Wheel at Maximum load of250Kg (2452.5N) = 0.145456mm Table-5: Result Analysis of different Material in Modified Design Material Deformation Equivalent Stress Aluminium Alloy Min 0.078027mm 16.801MPa Max 0.08778mm 18.901MPa PEEK Min 0.159336mm 15.997MPa Max 0.179253mm 17.997MPa PEEK 30% Min 0. mm 14.44MPa
  • 6. International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 06 Issue: 05 | May 2019 www.irjet.net p-ISSN: 2395-0072 © 2019, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 5011 glass fiber Max 0.160829mm 16.245MPa PEEK90H MF20 Min 0. mm 14.215MPa Max 0.29701mm 15.992MPa PEEK90H MF40 Min 0. mm 12.621MPa Max 0.145456mm 14.198MPa 3. RESULT AND DISCUSSION Table-6: Comparison Analysis Data of Different Material Material Analysis Data of Actual Wheel Analysis Data of Modified Wheel Total Deformat ion Equival ent Stress Total Deformat ion Equival ent Stress Alumin um Alloy Minim um 0.032467 mm 22.008 MPa 0.078027 mm 16.801 MPa Maxim um 0.036525 mm 24.76M Pa 0.08778 mm 18.901 MPa PEEK Minim um 0.066219 mm 20.579 MPa 0. mm 15.997 MPa Maxim um 0.074496 mm 23.152 MPa 0.179253 mm 17.997 MPa PEEK With 30% Glass Fiber Minim um 0.059457 mm 17.689 MPa 0. mm 14.44M Pa Maxim um 0.066899 mm 19.901 MPa 0.160829 mm 16.245 MPa PEEK - 90HMF 20 Minim um 0.109829 mm 17.26M Pa 0. mm 14.44M Pa Maxim um 0.123558 mm 19.418 MPa 0.29701 mm 15.992 MPa PEEK - 90HMF 40 Minim um 0.053907 mm 16.766 MPa 0. mm 12.621 MPa Maxim um 0.060645 mm 18.861 MPa 0.145456 mm 14.198 MPa Table-7: Comparison Data of Weight Material Actual Wheel Modified Wheel Percentage Reduction in Weight Aluminum Alloy 5.300Kg 4.956Kg 6.5% PEEK 2.844Kg 2.361Kg 55.45% PEEK30% Glass Fiber 3.275Kg 2.719Kg 48.69% PEEK90HMF20 2.952Kg 2.451Kg 53.75% PEEK90HMF40 3.125Kg 2.594Kg 51.05% From the above tables it is clear that modified wheel mass reduction is maximum 55.45 % in PEEK, after this it is 53.75% in PEEK90HMF20, 51.05% in PEEK90HMF40, 48.69% in PEEK30% Glass Fiber and minimum reduction in Aluminum Alloy i.e. 6.5% 3. CONCLUSION From the above tables & discussion it is clear that PEEK is Best material for the replace of Aluminium material. Weight of Aluminum Wheel: 5.300 Kg Cost of Aluminum Wheel: - 15-20K Weight of Plastic Wheel: - 2.361Kg Cost of Plastic Wheel: - 8-10K Author gets the success to achieve the reduction in wheel rim weight & saving the cost of wheel rim (PEEK) material. ACKNOWLEDGEMENT Author wants to say thanks to his guidefortheirsupport and guidance. Finally author wants to say thanks to all people who support him directly or indirectly during this work. REFERENCES [1] Emmanuel M Adigio, Ebughni O Nangi. Computer Aided Design and Simulation of Radial Fatigue Test of Automobile Rim Using ANSYS. IOSR Journal of Mechanical and Civil Engineering (IOSR-JMCE). 2014;11(1):68−73. [2] Mohammad Zeeshan, Om Prakash Tiwari & Anil Yadav (2018) The design and analysisofa motorcyclewheel by using ansys International Journal of Advance Engineering and ResearchDevelopmentVolume5,Issue 06, June -2018 [3] Yadav PH, Ramdasi PG. Optimization of Car Rim Using OptiStruct. IOSR Journal of Environmental Science, Toxicology and Food Technology (IOSR-JESTFT). 2012;2(3):10−15.
  • 7. International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 06 Issue: 05 | May 2019 www.irjet.net p-ISSN: 2395-0072 © 2019, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 5012 [4] M. Saran Theja1, M. Vamsi Krishna (2013) Structural and Fatigue Analysis of Two Wheeler Lighter Weight Alloy Wheel IOSR Journal of Mechanical and Civil Engineering (IOSR-JMCE) e-ISSN: 2278-1684,p-ISSN: 2320-334X, Volume 8, Issue 2 (Jul. - Aug. 2013) [5] Mr. Sasank Shekhar Panda, Mr. Dibya Narayan Behera, Mr. Satya Narayan Tripathy (2016) “modeling and structural analysis of alloy wheel using ANSYS” international journal of engineeringsciences&research technology. [6] Machine Design Book by R.S khurmi [7] K.N.D. Malleswara Rao (2016) “MODEL OPTIMIZATION AND STRUCTURAL ANALYSIS OF CAR RIM” research gate