Design optimization of aluminum rims in bending by finite element analysis

Abstract

This paper shows the process for optimization of structural design to fatigue bending aluminum wheels in a company located in the city of Manizales, Colombia. The process was conducted relating the finite element analysis with fatigue bending tests results, demonstrating that the design of aluminum wheels can be optimized by reducing the development time of each model, getting lighter wheels, which means savings cost of development and manufacturing of the product with consequent improvements in efficiency and performance of vehicles. Furthermore, if the simulation is performed early in the product development process, designs can be optimized prior to manufacture and testing of physical prototypes. The work presented shows how the finite element analysis has successfully incorporated as part of the wheels normal design process in the company, with consequent benefits in terms of reliability and productivity.