A new methodology based on LS-DYNA for integrating product & process engineering of a steel wheel

Wheels are products with key geometrical and structural specifications.

ABSTRACT

Wheels are products with key geometrical and structural specifications. The wheel must fulfil load, fatigue and weight requirements, as well as geometry, stiffness and environmental resistance. In addition, new style requirements are coming from the OEM’s. To satisfy these demands the wheel manufacturer must have a deep insight into new materials and manufacturing processes as well as a robust design methodology to correctly consider both process and product constraints.
Steel wheels for passenger cars and commercial vehicles usually consist of two parts: rim and disc. The rim is the part that is in contact with the tire: international norms regulate most of its geometrical characteristics to guarantee functionality of pieces developed by different wheel and tire manufacturers.
The disc is the part that provides the connection between the vehicle’s suspension (hub) and the rim. Except for its central part, which is imposed by the customer, the disc profile is less standardized than the rim since it needs to be designed by taking into account several variable interfaces (brake callipers, trims, …) and performance requirements (fatigue resistance, bolt hole resistance, …) which are specific for each project.

The first part of the article describes the whole manufacturing process as well as the currently used prototype and virtual testing techniques. Afterwards, a new methodology is presented, following an integrated process-product analysis approach, showing some benefits related to increased accuracy and the potential application of new optimization methods.

<p>A new methodology based on LS-DYNA for integrating product & process engineering of a steel wheel</p>

A new methodology based on LS-DYNA for integrating product & process engineering of a steel wheel

<p>Images of the wheel and its two components from a CAD model</p>

Images of the wheel and its two components from a CAD model

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