Design and comparative strength analysis of wheel rims of a lightweight electric vehicle using Al6063 T6 and Al5083 aluminium alloys

• Autorzy: Korkut T. B. , Armakan E. , Ozaydin O. , Ozdemir K. , Goren A.

Identyfikatory

DOI

10.5604/01.3001.0014.1776

• Języki publikacji: EN

Abstrakty

EN

Purpose: Use of aluminium alloys in critical parts of a vehicle is common since they can combine the two important properties of a material those are being strength and lightweight. The aim in this research is to guide to design process of a wheel with taking example of an electric race vehicle implementation. Design/methodology/approach: In this study, the fatigue strengths of wheels produced for a two-person racing electric vehicle (Demobil09) are evaluated by calculating maximum distortion energy criterion (Von Mises) with Finite Element Analysis. Findings: Aluminium alloy wheels are crucial safety related components and are subjected to static and dynamic loads directly. Using FEA results, the weight and equivalent stress of the wheel are both reduced. So, the energy consumption is also decreased. Modal frequencies of the wheel models are determined. Research limitations/implications: In this paper, the materials analysed are AL6063 T6 and Al5083 aluminium alloys. Different materials can be analysed in future works. Practical implications: This paper is focusing on how to reduce the energy consumption of a two-person electric vehicle concentrating on reducing the weight of vehicle wheels. The vehicle is more technological than mass production cars since it is an electric race car which uses a hub motor, the body and chassis are produced using carbon polymer composites and all electronic units are designed and produced. Although its specialities it has homologated safety equipment like seats and safety belts. Originality/value: All boundary conditions must be analysed in details and a strength analysis must be conducted during design of the wheels for different load cases to ensure the strength of a wheel while keeping the weight as low as possible. In this complex process, this paper can give some clues to designers for strengths and weights of the designs since three different wheel forms are evaluated for reducing energy consumption of the vehicle.

Słowa kluczowe

EN

aluminium alloy wheel; electric vehicle; stress analysis; energy consumption

PL

felgi aluminiowe; pojazd elektryczny; analiza naprężeń; zużycie energii

• Wydawca: International OCSCO World Press
• Czasopismo: Journal of Achievements in Materials and Manufacturing Engineering
• Rocznik: 2020
• Tom: Vol. 99, nr 2
• Strony: 57--63
• Opis fizyczny: Bibliogr. 11 poz., rys., tab., wykr.

Twórcy

autor

Korkut T. B.

• R&D Department, Cevher Wheels, 35411 Gaziemir, Izmir, Turkey
• Department of Mechanical Engineering, Dokuz Eylul University, 35380 Buca, Izmir, Turkey

autor

Armakan E.

• R&D Department, Cevher Wheels, 35411 Gaziemir, Izmir, Turkey

autor

Ozaydin O.

• R&D Department, Cevher Wheels, 35411 Gaziemir, Izmir, Turkey

autor

Ozdemir K.

• R&D Department, Cevher Wheels, 35411 Gaziemir, Izmir, Turkey

autor

Goren A.

• Department of Mechanical Engineering, Dokuz Eylul University, 35380 Buca, Izmir, Turkey

Bibliografia

• [1] J. Stearns, T.S. Srivatsan, A. Prakash, P.C. Lam, Modeling the Mechanical Response of an Aluminium Alloy Automotive Rim, Materials Science and Engineering: A 366/2 (2004) 262-268. DOI: https://doi.org/10.1016/j.msea.2003.08.017
• [2] H Akbulut, On optimization of a car rim using finite element method, Finite Elements in Analysis and Design 39/5-6 (2003) 433-443. DOI: https://doi.org/10.1016/S0168-874X(02)00091-4
• [3] M. Tebaldini, C. Petrogalli, G. Donzella, G.M. La Vecchia, Estimation of Fatigue Limit of a A356-T6 Automotive Wheel in Presence of Defects, Procedia Structural Integrity 7 (2017) 521-529. DOI: https://doi.org/10.1016/j.prostr.2017.11.121
• [4] D.M. Maijer, W.S. Owen, R.A. Vetter, An investigation of predictive control for aluminium wheel casting via a virtual process model, Journal of Materials Processing Technology 209/4 (2009) 1965-1979. DOI: https://doi.org/10.1016/j.jmatprotec.2008.04.057
• [5] J. Hu, X. Liu, H. Sun, Z. Zhu, B. Li, Development and Application of Light-weight Design of the Aluminium Alloy Wheel, Applied Mechanics and Materials 310 (2013) 253-257. DOI: https://doi.org/10.4028/www.scientific.net/AMM.310.253
• [6] Z. Zhang, H. Jia, J. Sun, M. Wang, Application of Topological Optimization on Aluminium Alloy Automobile Wheel Designing, Advanced Materials Research 562-564 (2012) 705-708. DOI: https://doi.org/10.4028/www.scientific.net/AMR.562-564.705
• [7] T. Hobeika, S. Sebben, CFD investigation on wheel rotation modelling, Journal of Wind Engineering and Industrial Aerodynamics 174 (2018) 241-251. DOI: https://doi.org/10.1016/j.jweia.2018.01.005
• [8] P. Lengvarský, J. Bocko, Theoretical Basis of Modal Analysis, American Journal of Mechanical Engineering 1/7 (2013) 173-179. Available from: http://pubs.sciepub.com/ajme/1/7/4
• [9] C. Bosi, G.L. Garagnani, R. Toyo, Fatigue Properties of A Cast Aluminium Alloy For Rims of Car Wheels, Metallurgical Science and Technology 20/1 (2002) 3-8.
• [10] M. Yaman, Finite Element Modelling and Validation of a Light Commercial Vehicle Wheel, M.Sc. Thesis, Istanbul Technical University, Istanbul, Turkey.
• [11] P. Kindt, P. Sas, W. Desmet, Development and validation of a three-dimensional ring-based structural tyre model, Journal of Sound and Vibration 326/3-5 (2009) 852-869. DOI: https://doi.org/10.1016/j.jsv.2009.05.019

Uwagi

PL

Opracowanie rekordu ze środków MNiSW, umowa Nr 461252 w ramach programu "Społeczna odpowiedzialność nauki" - moduł: Popularyzacja nauki i promocja sportu (2020).