Design and comparative strength analysis of wheel rims of a lightweight electric vehicle using Al6063 T6 and Al5083 aluminium alloys

Abstract

Purpose: Use of aluminium alloys in critical parts of a vehicle is common since they can combine the two important properties of a material those are being strength and lightweight. The aim in this research is to guide to design process of a wheel with taking example of an electric race vehicle implementation. Design/methodology/approach: In this study, the fatigue strengths of wheels produced for a two-person racing electric vehicle (Demobil09) are evaluated by calculating maximum distortion energy criterion (Von Mises) with Finite Element Analysis. Findings: Aluminium alloy wheels are crucial safety related components and are subjected to static and dynamic loads directly. Using FEA results, the weight and equivalent stress of the wheel are both reduced. So, the energy consumption is also decreased. Modal frequencies of the wheel models are determined. Research limitations/implications: In this paper, the materials analysed are AL6063 T6 and Al5083 aluminium alloys. Different materials can be analysed in future works. Practical implications: This paper is focusing on how to reduce the energy consumption of a two-person electric vehicle concentrating on reducing the weight of vehicle wheels. The vehicle is more technological than mass production cars since it is an electric race car which uses a hub motor, the body and chassis are produced using carbon polymer composites and all electronic units are designed and produced. Although its specialities it has homologated safety equipment like seats and safety belts. Originality/value: All boundary conditions must be analysed in details and a strength analysis must be conducted during design of the wheels for different load cases to ensure the strength of a wheel while keeping the weight as low as possible. In this complex process, this paper can give some clues to designers for strengths and weights of the designs since three different wheel forms are evaluated for reducing energy consumption of the vehicle.

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