Optimization of Magnesium Alloy Wheel Dynamic Impact Performance

Abstract

Designing lightweight and comfortable automotive vehicles is a primary aim of the industry. Lightweight wheel designs can have a negative effect on the dynamic impact performance of the wheel; therefore, striking a balance between these two factors is a key objective in the design of automotive vehicles. Magnesium alloy wheels were investigated as magnesium alloy has damping performance advantages over some metal materials. Damping test methods were designed to establish the damping performance parameters of the magnesium alloy material. A finite element analysis model of magnesium alloy wheels was established with certain boundary conditions and constraints. The applicability of the model was verified by free modal evaluation of the wheel. Dynamic impact simulation analysis of the designed wheels was carried out, and the dynamic speed responses of magnesium alloy wheels under the impact of a dynamic load on the road surface were obtained. Comparison of the dynamic impact performance of magnesium and aluminum alloy wheels with the same structure showed that the magnesium alloy wheel achieved the target weight reduction of 32.3%; however, the dynamic impact performance was reduced. In order to realize the lightweight design, the dynamic impact performance of the magnesium alloy wheel should not be inferior to that of the aluminum alloy wheel; therefore, the design of the magnesium alloy wheel structure was optimized. The structural design optimization of the magnesium alloy wheel was carried out by defining the structural parameters of the wheel and using the acceleration and shock response of the wheel as the outputs. The optimization of weight reduction and dynamic impact performance of magnesium alloy wheels was achieved. Consequently, the designed magnesium alloy wheel was shown to have improved ride comfort while satisfying wheel structural performance standards and providing lightweight design.

Applications of High-Pressure Die-Casting (HPDC) Magnesium Alloys in Industry

“…A die-cast AM60 magnesium wheel was used for the 2015 Yamaha YZF-R1 motorcycle which improved the vehicle maneuverability and handling stability [77]. The advantages and disadvantages of using magnesium automotive wheels were also investigated [78][79][80]. However, the high cost and corrosion concerns of magnesium alloys restrict their application on automotive wheels.…”

Study on casting design and analysis of magnesium alloy wheel

“…Dynamic tests and vibration analysis were carried out on actual casting wheels, and the wheels were installed onto a vehicle (Jiang et al , 2019). Thus, the feasibility of using the designed wheel in actual applications is demonstrated.…”

Effect of T4 treatment on the corrosion resistance of Mg-4Al-6Er-0.3Mn alloy

“…Magnesium alloys emerged as a promising candidate for lightweight structural materials [1][2][3][4] in engineering applications due to their low density [5], high specific strength [6], good damping [7,8] and electromagnetic shielding [9,10]. The magnesium alloys have the potential for wide application fields such as aerospace, automotive, and telecommunications [11][12][13].…”