Abstract. This paper establishes a numerical procedure to predict the aluminum wheel performance during the impact test. The dynamic finite element solver, Ansys-Lsdyna970, is used. In order to save the computation time, the striker is assigned with an initial velocity, which is equal to the velocity reached during the free-fall period upon release. Mass scaling method is also utilized to further reduce computational time. Equivalent plastic strain is used as the damage indicator to judge pass or fail for the dynamic impact test. The true stress-strain curve is obtained from a uni-axial tensile test of A356-T6 samples machined from a prototype wheel. Simulation results show that plastic deformation tends to be localized around spoke-to-hub junction area. Studies on a recent prototype wheel revealed good correlation between experimental results and numerical prediction.
IntroductionImpact performance is critical for wheels to ensure vehicle safety and drive quality. This procedure establishes the minimum performance requirements for wheels of the passenger car, SUV and light truck. A wheel is usually consisted by 5 regions, which are hub, spoke, rim, flange and window, as shown in Fig.1. The wheel also needs to pass the multiple checks to ensure that it is not damaged prior to the test. At the same time, the numerical simulations of wheel impact test are essential in the wheel development process, which can reduce design time, especially for prototype building or concept verification in the early product development phase. When it is appropriately carried out, nonlinear finite element analysis can help engineer to validate the wheel design. Therefore, physical impact tests can be reduced or even eliminated after establishing the correlation between numerical simulation and lab impact test.