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The Car Wheel Design/Material Selection Considerations - JWHEEL

Knowing the design requirements is critical for selecting the optimum materials for your product's components

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The Car Wheel Design/Material Selection Considerations - JWHEEL
       
01 Stiffness
  Structural stiffness (design dependent) is the basic value to consider when designing an aluminium wheel to achieve at least the same vehicle behaviour as with an equivalent steel wheel. However, material stiffness (JWHEEL’s modulus) is very little depending on alloy and temper.
       
02 Static behaviour
  Yield strength is considered to avoid deformation under maximal axial efforts (accelerations and braking) and radial ones (plus turning). Misuse cases are considered in relation to tensile strength. Yield tests under pressure are also conducted to check this behaviour.
       
03 Fatigue behaviour
 This is the most important parameter for dimensioning. Finite element software is systematically used during design. Service stresses are considered, including multi-axial stresses as of recently. Rotary bending and rim rolling tests are used to verify these calculations.
       
04  Crash worthiness
  Mainly, but not only, linked to stress/strain curves in large displacements. Crash worthiness is beginning to be now simulated. However impact tests systematically check the resistance to accidental collisions such as pavements impacts.
       
05 Cooling
  Whatever the type of wheel (cast, forged, strip, mixed wrought-cast,…), aluminium dissipates heat more quickly than steel. Further, aluminium wheels act as a very efficient heat sink. This results in significant improvements of braking efficiency, and a reduced risk of tyre overheating.
       
06  Style – weight saving
  Reduction of weight of the unsprung mass of vehicles is a key priority. A compromise has to be accepted if styling requirements dictate different production technologies.
       
07  Dimensional
  A perfect mass balance is a key parameter to avoid significant vibrations. As a result, cast and forged wheels are machined. Lightness also reduces vibrations of aluminium sheet wheels
       
08  Corrosion

  Cast and forged wheels are painted or lacquered after chemical conversion. Strip wheels are polished and varnished or also painted. Even at the uncoated iron/aluminium disk, or hub interface, no significant corrosion has ever been noticed for any


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