Topology Optimization of Aluminium Alloy Wheel

A great number of wheel tests are required in designing and manufacturing of wheels to meet satisfactory requirements. The impact performance of a wheel is the major concern. Numerical implementation of impact test is essential to shorten the design time, improve the mechanical performance and lower development cost. Project includes the “Topology Optimization of Cast Aluminium Alloy wheel” using impact analysis. Since the fail value of plastic strain for standard Cast Aluminium Alloy Wheel is 4.0%, cracks will appear if the Plastic Strain value is greater than 4%. This analysis will predict the plastic strain0s induced during impact testing. Topology Optimization is carried out by increasing the thickness of the rim until the plastic strain value is below 4%. The main objective of the project is to generate a Finite element model (Hexa & Penta elements) using Hypermesh V10.0 with all the properties, materials, loads and Boundary conditions as specified by the client. Impact analysis is carried out using LS-Dyna software to predict the plastic strains during impact test. Topology Optimization is carried out by changing the thickness of the rim of the Cast Aluminium Alloy Wheel until the value of the plastic strain is less than 4.0%.