Static Loading, Fatigue Analysis, and Shape Optimization of an Aluminum Rim
Updated: Jun 18
Subject to Dynamic Cornering Fatigue
CAE/FEA Engineer at Aventec
As a critical component of the vehicle, automotive wheels must meet strict safety requirements. The dynamic cornering fatigue test is a required standard by SAE. The test simulates cornering induced loads to the wheel, and it is commonly known to be the most severe test to pass in the industry.
Meeting the requirements of this test requires an extensive amount of resources, especially at the development stage where design iterations and field measurements are combined to come up with a reliable design. Furthermore, the complex shape and geometry of wheel designs make it hard to rely fully on an analytical solution for fatigue analysis.
In this work, I performed a numerical simulation of the dynamic cornering fatigue test using Abaqus/CAE and Fe-Safe. Three different methodologies were presented to model the wheel bending moment. Shape optimization using Tosca was also performed to optimize the fatigue life of the wheel design.
To push the complexity of the study furthermore, I performed a fatigue-based shaped optimization combining outputs from Fe-Safe with Tosca and Abaqus/CAE. The results showed that a reliable optimization solution should consider the fatigue induced damage rather than the static solution.
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