Topology optimization and testing of car alloy wheel subjected to varying loads.

Aluminum and magnesium alloys are used to make alloy rims in the automotive sector. In contrast to pure metals, alloys are combinations of metals and other elements with a higher strength level. A 3D model can be used to generate a design space via topology optimization, a mathematical approach. To make the design more efficient, it then eliminates or displaces material within it. When mixing materials, the objective function does not take aesthetics or manufacturing ease into account. At the very least, we need to tell the technique how much weight it can handle and how far it can go. Because the spokes and hub area are smaller, they contribute less weight to an aluminum alloy wheel rim. The topology optimization is carried out on a car wheel rim in ANSYS, and stress analysis is done on the rim body before and after optimization. The von-mises stresses induced in the wheel rim before optimizations are 3.3MPa and the stresses caused after optimization are 3.25MPa. This is a reduction of 0.5MPa from the original model, which is considered in the tolerance limit. Whereas the reduction in the mass density of the alloy wheel rim was about 17.4% which was achieved corresponding to the following optimization using simulations with a 70% retention rate in volume. [ABSTRACT FROM AUTHOR]