Shape optimisation of rim structure of aluminium alloy car wheels based on 90° impact test
Abstract Automotive wheels are critical components for vehicular safety, with the rim subjected primarily to radial bending loads during operation. Balancing rim thickness and structural integrity under these loading conditions is imperative. This paper develops and validates an innovative shape opt...
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| Format: | Article |
| Language: | English |
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Nature Portfolio
2025-07-01
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| Series: | Scientific Reports |
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| Online Access: | https://doi.org/10.1038/s41598-025-07802-z |
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| author | Guangdong Zhang Shike Tao Yangyang Zhou Zhen Ye Jianjun Lu Risheng Li Shihui Li Linzhen Zhou Tong Deng |
| author_facet | Guangdong Zhang Shike Tao Yangyang Zhou Zhen Ye Jianjun Lu Risheng Li Shihui Li Linzhen Zhou Tong Deng |
| author_sort | Guangdong Zhang |
| collection | DOAJ |
| description | Abstract Automotive wheels are critical components for vehicular safety, with the rim subjected primarily to radial bending loads during operation. Balancing rim thickness and structural integrity under these loading conditions is imperative. This paper develops and validates an innovative shape optimisation approach utilising the 90° wheel impact test methodology. A simplified 2D finite element model was formulated for rim optimisation to address the computational inefficiency of conventional 3D simulation-based optimisation in product development while exploiting rim geometry’s rotational symmetry. The design of experiments technique was employed to identify key stiffness-influencing factors and their interactions. Subsequent shape optimisation, guided by analytical insights, yielded an engineered rim configuration. Comparative 3D simulations of 90° impact performance demonstrated a 0.51 mm reduction in inner rim flange deformation alongside a 59 g mass reduction, achieving dual objectives of enhanced structural performance and lightweighting. This streamlined optimisation methodology significantly enhances development efficiency while providing engineers with critical insights into parametric influences on rim strength characteristics. |
| format | Article |
| id | doaj-art-d026601c17a24b5b82e058eb4efd12b2 |
| institution | Kabale University |
| issn | 2045-2322 |
| language | English |
| publishDate | 2025-07-01 |
| publisher | Nature Portfolio |
| record_format | Article |
| series | Scientific Reports |
| spelling | doaj-art-d026601c17a24b5b82e058eb4efd12b22025-08-20T04:02:45ZengNature PortfolioScientific Reports2045-23222025-07-0115111410.1038/s41598-025-07802-zShape optimisation of rim structure of aluminium alloy car wheels based on 90° impact testGuangdong Zhang0Shike Tao1Yangyang Zhou2Zhen Ye3Jianjun Lu4Risheng Li5Shihui Li6Linzhen Zhou7Tong Deng8School of Mechanical Engineering, Yancheng Institute of TechnologySchool of Mechanical Engineering, Yancheng Institute of TechnologyHebei High Strength and Toughness Lightweight Wheel Technology Innovation Centre, Baoding Lizhong Wheel Manufacturing Co., Ltd.Hebei High Strength and Toughness Lightweight Wheel Technology Innovation Centre, Baoding Lizhong Wheel Manufacturing Co., Ltd.Hebei High Strength and Toughness Lightweight Wheel Technology Innovation Centre, Baoding Lizhong Wheel Manufacturing Co., Ltd.Hebei High Strength and Toughness Lightweight Wheel Technology Innovation Centre, Baoding Lizhong Wheel Manufacturing Co., Ltd.Hebei High Strength and Toughness Lightweight Wheel Technology Innovation Centre, Baoding Lizhong Wheel Manufacturing Co., Ltd.School of Mechanical Engineering, Yancheng Institute of TechnologyThe Wolfson Centre for Bulk Solids Handling Technology, Faculty of Engineering and Science, University of GreenwichAbstract Automotive wheels are critical components for vehicular safety, with the rim subjected primarily to radial bending loads during operation. Balancing rim thickness and structural integrity under these loading conditions is imperative. This paper develops and validates an innovative shape optimisation approach utilising the 90° wheel impact test methodology. A simplified 2D finite element model was formulated for rim optimisation to address the computational inefficiency of conventional 3D simulation-based optimisation in product development while exploiting rim geometry’s rotational symmetry. The design of experiments technique was employed to identify key stiffness-influencing factors and their interactions. Subsequent shape optimisation, guided by analytical insights, yielded an engineered rim configuration. Comparative 3D simulations of 90° impact performance demonstrated a 0.51 mm reduction in inner rim flange deformation alongside a 59 g mass reduction, achieving dual objectives of enhanced structural performance and lightweighting. This streamlined optimisation methodology significantly enhances development efficiency while providing engineers with critical insights into parametric influences on rim strength characteristics.https://doi.org/10.1038/s41598-025-07802-zRimDesign of experimentsShape optimisation90° impact simulation |
| spellingShingle | Guangdong Zhang Shike Tao Yangyang Zhou Zhen Ye Jianjun Lu Risheng Li Shihui Li Linzhen Zhou Tong Deng Shape optimisation of rim structure of aluminium alloy car wheels based on 90° impact test Scientific Reports Rim Design of experiments Shape optimisation 90° impact simulation |
| title | Shape optimisation of rim structure of aluminium alloy car wheels based on 90° impact test |
| title_full | Shape optimisation of rim structure of aluminium alloy car wheels based on 90° impact test |
| title_fullStr | Shape optimisation of rim structure of aluminium alloy car wheels based on 90° impact test |
| title_full_unstemmed | Shape optimisation of rim structure of aluminium alloy car wheels based on 90° impact test |
| title_short | Shape optimisation of rim structure of aluminium alloy car wheels based on 90° impact test |
| title_sort | shape optimisation of rim structure of aluminium alloy car wheels based on 90° impact test |
| topic | Rim Design of experiments Shape optimisation 90° impact simulation |
| url | https://doi.org/10.1038/s41598-025-07802-z |
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