Wheel Material Engineering: Design, Simulation and Performance Evaluation for Automobiles

Abstract

This study presents a comparative analysis of three different wheel rim designs using Finite Element Analysis (FEA) in ANSYS. The objective is to assess and optimize the performance, safety, and material efficiency of each design under static structural loading. Materials considered include Aluminum, Magnesium, and Titanium alloys. Simulations involve stress distribution, total deformation, fatigue life, and safety factor. Results reveal critical insights into structural resilience and suggest optimal designs for improved safety and sustainability in automotive applications. The primary objective of this analysis is to identify the optimal wheel design by evaluating two critical factors: performance and material efficiency. Performance is measured through metrics like von-Mises stress, which assesses the material's response to complex stress states, and total deformation, which examines the extent of shape changes under load. Material efficiency is considered by determining how effectively each design achieves high performance while minimizing material usage. This balance is crucial for modern manufacturing, where reducing weight, cost, and environmental impact is increasingly prioritized.