Fatigue Life Simulation of an Alloy Wheel Design
Keywords:Alloy wheel, Design, Fatigue Life, Finite element analysis, Simulation.
Finite element analysis (FEA) is extensively used in the engineering field, especially in structural engineering. FEA is a numerical method used for solving engineering problems that involve complicated geometries, various loading conditions and material properties. A fatigue life assessment of an engineering component is necessary to predict the life span of this component before failure. Automobile alloy wheel is an engineering component that is exposed to fatigue failure in services. Therefore, this study aims to determine the critical area for crack initiation on automobile alloy wheel and to simulate and analyse the fatigue life of an automobile alloy wheel design that is fabricated from different types of materials. The automobile alloy wheel design was modelled using computer-aided design and analysed using commercial finite element software. The automobile alloy wheel was modelled based on a 1200 cc national automobile. Three types of materials, namely, titanium, aluminium and magnesium alloys, were used in this study. A critical part of a steering knuckle could be identified by conducting a stress analysis, and the fatigue life of the automobile alloy wheel could be predicted on the basis of applied loads. Results showed that fatigue life is significantly influenced by the types of material used in a simulation.
 Suman S, Abrol JA & Ravi K, â€œImpact and modal analysis for different alloy wheel Compositionsâ€, IOP Conference Series: Materials Science and Engineering, Vol. 263, (2017), pp. 1-10.
 Torgal S & Mishra S, (2012) â€˜Stress analysis of wheel rimâ€™, International Journal of Mechanical Engineering and Research, Vol. 1, (2012), pp. 34-37.
 Hadley SW, Das S & Miller JW, â€œAluminium R & D for automotive uses and the Department of Energyâ€™s Roleâ€, Technical Report, U.S. Department of Energy, Washinton, (2000).
 Musfirah AH & Jaharah A, â€œMagnesium and aluminium alloys in automotive industry, Journal of Applied Science Research, Vol. 8, No. 9, (2012), pp. 4865â€“4875.
 Fleming S, â€œAn overview of magnesium based alloys for aerospace and automotive applicationsâ€, Masterâ€™s Thesis, Rensselaer Polytechnic Institute Hartford, (2012).
 Balwert C, Hort N, & Kainer KU. â€œAutomotive applications of magnesium and its alloysâ€, Transactions of Indian Institute of Metals, Vol. 57 No. 4, (2004), pp. 397â€“408.
 Zakaria KA, Jimit RH, Ramli SNR, Aziz AA, Bapokutty O & Ali MB, â€œStudy on fatigue life and fracture behavior of fiberglass reinforced composites, Journal of Mechanical Engineering and Sciences, Vol. 10, No. 3, (2016), pp. 2300-2310.
 Zakaria KA, Suhadak FHA, Ali MB, Abdullah S, Ghazali MJ, â€œInfluence of mechanical properties on load sequence effect and fatigue life of aluminium alloysâ€, Journal of Mechanical Engineering and Sciences, Vo. 11, No. 1, (2017), pp. 2469-2477.
 Shighley JE, Mischake CR, Mechanical Engineering Design, Six Metric Edition, New York, McGrawHill, (2003).
 Post NL, Case SW, Lesko JJ, â€œModelling the variable amplitude fatigue of composite materials: A review and evaluation of the state of the art for spectrum loadingâ€, International Journal of Fatigue, Vol. 30, (2008), pp. 2064-2086.
 Callister WD, Material Science and Engineering, New York, John Wiley & Son, (2007).
 Zakaria KA, Abdullah S & Ghazali MJ, â€œA review of the loading sequence effects on the fatigue life behaviour of metallic materialsâ€, Journal of Engineering Science and Technology Review, Vol. 9, No. 5, (2016), pp. 189-200.
 Singh J & Saha S, â€œSatatic analysis of alloy wheel using Ansys 15.0â€, International Journal of Research in Engineering and Technology, Vol. 4, No. 7, (2015), pp. 217-220.
 Zakaria KA, Abdullah S, Ghazali MJ, â€œElevated temperature fatigue life investigation of aluminium alloy based on the predicted
S-N curveâ€, Jurnal Teknologi, Vol. 63, No.1 (2013), pp. 75-79.
 Doyle MM, â€œThe design of an aluminium alloy wheel using three-dimensional finite element analysis and fatigue life predictionâ€, Masterâ€™s Thesis, Dublin City University, (1996).
 Martinez A, Jaimes A, Serna A & Uribe I, â€œDevelopment of a correlation estimate the fatigue strength for steel based on low cost testsâ€, Journal Cencia, Technology & Future, Vo. 4, No. 2, (2010), pp. 71-81.
 Zakaria KA, Abdullah S & Ghazali MJ, â€œComparative study of fatigue life behaviour of AA6061 and AA7075 alloys under spectrum loadingsâ€, Materials and Design, Vol. 49, (2013), pp. 48-57.