Lightweight Design of SUV Automobile Aluminum Alloy Wheel Hub Based on Finite Element Simulation

doi:10.12068/j.issn.1005-3026.2025.20230192

Abstract

Abstract:

Based on the finite element analysis and performance testing， the lightweight design of aluminum alloy wheel hub is carried out. Firstly， the structural static analysis of the wheel hub model is carried out to obtain the stress and deformation distribution of the wheel hub under the static full load state of the vehicle using ANSYS Workbench. Secondly， through the analysis of the first six‑order modes of the wheel hub， the natural frequency and deformation of each order of the wheel hub are obtained， and the resonance law of the wheel hub excited by the engine and the road is proved. Then， according to the wheel hub’s bending fatigue， radial fatigue and impact simulation tests， the topology optimization of the wheel hub spokes is carried out and a lightweight wheel hub model is obtained. Finally， the lightweight wheel hub is tested again， and the testing results of the lightweight wheel hub and the original wheel hub are compared to obtain the performance changes of the wheel hub before and after optimization， so as to ensure that the lightweight wheel hub model still meets the requirement for strength.

Key words: wheel hub, lightweight design, topology optimization, finite element analysis, performance test

CLC Number:

R 331.3

Xiao-ming CHEN, Jian-ye YU, Shun LIU, Chong ZENG. Lightweight Design of SUV Automobile Aluminum Alloy Wheel Hub Based on Finite Element Simulation[J]. Journal of Northeastern University(Natural Science), 2025, 46(1): 99-109.

Figures/Tables 21

Table 1 Vehicle parameters

整车质量/kg	最大功率/kW	最大扭矩/（N·m）	变速器传动效率/%	一档传动比	主减速比
1 865	138	252	95	3.5	4.356

Fig.1 Original wheel hub model and constraint

Table 2 Material properties of A356 aluminum alloy

密度 $ρ$	弹性模量 $E$	泊松比 $μ$	屈服强度
$k g · m - 3$	$G P a$	泊松比 $μ$	$M P a$
2 700	72.4	0.33	239

Table 2 Material properties of A356 aluminum alloy

密度 $ρ$	弹性模量 $E$	泊松比 $μ$	屈服强度
$k g · m - 3$	$G P a$	泊松比 $μ$	$M P a$
2 700	72.4	0.33	239

Fig.2 Load application diagram for static analysis

Fig.3 Static analysis cloud map

Fig.4 Modal analysis cloud map

Fig.5 Constraint and load for bending fatigue testing

Table 3 Corresponding quivalent stress values at different angular

角度/（°）	等效应力/MPa	角度/（°）	等效应力/MPa	角度/（°）	等效应力/MPa	角度/（°）	等效应力/MPa
5	102.64	50	103.79	95	109.12	140	106.18
10	105.99	55	103.47	100	112.19	145	104.56
15	108.56	60	102.74	105	114.42	150	102.73
20	110.34	65	102.62	110	115.81	155	102.11
25	111.29	70	104.55	115	116.34	160	102.80
30	111.42	75	105.70	120	116.00	165	102.92
35	110.73	80	106.06	125	114.80	170	102.28
40	109.22	85	105.64	130	112.75	175	100.87
45	106.90	90	105.24	135	109.87	180	101.02

Fig.6 Quivalent stress distribution cloud map of multi-direction of bending fatigue testing

Fig.7 Stress and deformation cloud map of radial fatigue testing

Table 4 Velocity changes of the hammer

t/s	Y轴方向速度/（mm·s^-1）
0.029 6	-248.62
0.029 8	-121.72
0.030 0	18.052
0.030 2	162.79

Fig.8 Stress and deformation cloud map of

Fig.9 Process of topology optimization

Fig.10 Topology optimization results

Fig.11 Model after lightweight design

Fig.12 Model static analysis cloud map after lightweight design

Fig.13 Modal analysis cloud map after lightweight design

Fig.14 Stress cloud map of bending fatigue testing after lightweight design

Fig.15 Stress and deformation cloud map of radial fatigue testing after lightweight design

Fig.16 Stress and deformation cloud map of impact testing after lightweight design

Table 5 Comparison of data before and after lightweight design

参数

质量/kg

一阶固有频率/Hz

静态结构

最大应力

弯曲疲劳试验

最大应力

径向疲劳试验

最大应力

冲击试验

最大应力

References 23

1	Ridha R A.Finite element analysis of automatic wheels［J］.SAE Automotive Engineering Congress and Exposition，1976，85（1）：760085.
2	Shah V， Patel P， Keshav M.Modeling and analysis of integrated wheel hub［J］.Journal of Physics：Conference Series，2022，2256：012035.
3	Käumle F， Schnell R.Entwicklungszeit von Leichtmetallrädern verkürzen［J］.Materials Testing，1998，40（10）：394-398.
4	Topaç M M， Ercan S， Kuralay N S.Fatigue life prediction of a heavy vehicle steel wheel under radial loads by using finite element analysis［J］.Engineering Failure Analysis，2012，20：67-79.
5	Muthuraj R， Badrinarayanan R， Sundararajan T.Improvement in the wheel design using realistic loading conditions—FEA and experimental stress comparison［C］//16th Asia Pacific Automotive Engineering Conference.Pune：the Automotive Research Association of India，2011：280106.
6	Karandikar H M， Fuchs W.Fatigue life prediction for wheels by simulation of the rotating bending test［J］.SAE Transactions，1990，99：180-190.
7	Ferran G， Barros C R M， di Pasquale E，et al.Simplified numerical simulation of forming a car wheel disk using the SIMEX explicit FEM code，and comparisons with press‑shop results［J］.Journal of Materials Processing Technology，1996，60（1/2/3/4）：523-528.
8	Abe Y， Mori K， Ebihara O.Optimisation of the distribution of wall thickness in the multistage sheet metal forming of wheel disks［J］.Journal of Materials Processing Technology，2002，125：792-797.
9	秦德申.轿车车轮动态应力的测试与分析［J］.汽车工程，1989（4）：58-65.
	Qin De‑shen.Test and analysis of the dynamic stress of car wheels［J］.Automotive Engineering，1989（4）：58-65.
10	孙建鹏.铝合金轮毂设计分析平台的建立及疲劳寿命研究［D］.合肥：合肥工业大学，2014.
	Sun Jian‑peng.Establishment of design and analysis platform and fatigue life research of wheel hub［D］.Hefei：Hefei University of Technology，2014.
11	宋渊.铝合金轮毂轻量化设计（CAE）［D］.合肥：合肥工业大学，2014.
	Song Yuan.Lightweight design of aluminum alloy wheel hubs（CAE）［D］.Hefei：Hefei University of Technology，2014.
12	王科，王国林，朱志武.基于有限元法的汽车轮毂强度分析［J］.机械工程师，2013（1）：32-33．
	Wang Ke， Wang Guo‑lin， Zhu Zhi‑wu.Strength analysis of automobile wheels based on the finite element method［J］.Mechanical Engineer，2013（1）：32-33.
13	王倩倩，王静，韩欣欣.基于ANSYS Workbench的越野汽车轮毂有限元分析及优化［J］.汽车实用技术，2022（4）：72-75.
	Wang Qian‑qian， Wang Jing， Han Xin‑xin.Finite element analysis and optimization of off‑road vehicle wheels based on ANSYS Workbench［J］.Automobile Applied Technology，2022（4）：72-75.
14	Sinokrot T， Nakhaeinejad M， Shabana A A.A velocity transformation method for the nonlinear dynamic simulation of railroad vehicle systems［J］.Nonlinear Dynamics，2008，51（1）：289-307.
15	Stearns J， Srivatsan T S， Gao X，et al.Analysis of stress and strain distribution in a vehicle wheel：finite element analysis versus the experimental method［J］.The Journal of Strain Analysis for Engineering Design，2005，40（6）：513-523.
16	Hawkins G， Kumar V.Structural analysis of alloy wheels［J］.Journal of Physics：Conference Series，2020，1478：012007.
17	Marron G， Teracher P.The application of high‑strength，hot‑rolled steels in auto wheels［J］.JOM，1996，48（7）：16-20.
18	Raju P R， Satyanarayana B， Ramji K，et al.Evaluation of fatigue life of aluminum alloy wheels under radial loads［J］.Engineering Failure Analysis，2007，14（5）：791-800.
19	Riesner M， DeVries R I.Finite element analysis and structural optimization of vehicle wheels［C］//International Congress & Exposition.Detroit，1983：830133.
20	Karthikeyan K， Kishore R， Jeeva K，et al.Topology optimization of an ATV wheel hub［J］.Journal of Physics：Conference Series，2021，2027：012022.
21	肖占龙，孙跃东.基于ANSYS的汽车轮毂的轻量化研究［J］.农业装备与车辆工程，2022，60（2）：143-148.
	Xiao Zhan‑long， Sun Yue‑dong.Research on the lightweight of automobile wheels based on ANSYS［J］.Agricultural Equipment & Vehicle Engineering，2022，60（2）：143-148.
22	Pang W， Wang W P， Zhang W H，et al.Modeling and optimization for lightweight design of aluminum alloy wheel hub［J］.Key Engineering Materials，2016，723：322-328.
23	Chu D M， Bai W J， He Y，et al.Research on lightweight technology of new carbon fiber wheel hub structure［J］.IOP Conference Series：Earth and Environmental Science，2021，632（5）：052071.

[1]	Xian-zhen HUANG, Rui YU, Zhi-yuan JIANG, Zhi-ming RONG. Modeling and Reliability Global Sensitivity Analysis of Motorized Spindles Considering Thermal Errors [J]. Journal of Northeastern University(Natural Science), 2024, 45(5): 675-682.
[2]	Fa-xing DING, Kai-yuan LUO, Jian-xiong LEI, Fei LYU. Seismic Behavior Analysis of Single Side Bolt Joint of CFST Column-Composite Beam Under High Axial Compression [J]. Journal of Northeastern University(Natural Science), 2024, 45(12): 1787-1797.
[3]	Fa-xing DING, Shu-dong SHU, Jing-ke ZHANG, Chang HE. Mechanical Performance of Open Cross-Section Steel-Concrete Composite Beams Under Pure Torsion [J]. Journal of Northeastern University(Natural Science), 2024, 45(10): 1485-1493.
[4]	ZHANG Dong-xiang， ZHANG Chi， FAN Wei， GUO Li-xin. Effect of the Size of Artificial Vertebral Body on the Mechanical Properties of Cervical Spine [J]. Journal of Northeastern University(Natural Science), 2023, 44(8): 1136-1143.
[5]	AN Guo-qing， WANG Rui， ZHAO Hui， LI Tie-ying. Dynamic Response of Double-Skin Steel-Concrete Composite Panel Under Impact Loading [J]. Journal of Northeastern University(Natural Science), 2022, 43(8): 1192-1200.
[6]	WANG Lian-guang， MENG Yu-qi， WANG Zi-qing. Connection of Precast Profiled Steel Sheet Concrete Composite Plate and Steel Beam and Its Finite Element Analysis [J]. Journal of Northeastern University(Natural Science), 2022, 43(4): 575-581.
[7]	CHEN Xiao-hui， ZHANG Heng， LIU Ming-yue， HOU Dong-xiao. Finite Element Analysis of Tensile Failure of Open-Pored Carbon Fiber Composite Laminates [J]. Journal of Northeastern University(Natural Science), 2022, 43(3): 397-403.
[8]	ZHANG Yao-man， LI Wan-peng， YANG Ming-yu. Milling Force Characteristics of Titanium Alloy Parts Machined by Ball-end Milling Cutter [J]. Journal of Northeastern University Natural Science, 2020, 41(6): 852-857.
[9]	HUANG Zhi， WU Xiang， WANG Hong-yan， ZHOU Tao. Topological Optimization Design of Blade-Type Grinding Head Structure for Integral Blade Disk Polishing Machine [J]. Journal of Northeastern University Natural Science, 2019, 40(8): 1149-1153.
[10]	LI Jun-chao， XIE Feng， ZHAO Ze， GONG Peng-cheng. Numerical Simulation and Fracture Prediction of Incremental Sheet Forming of Metals [J]. Journal of Northeastern University Natural Science, 2019, 40(4): 488-494.
[11]	FAN Li ， XIE Li-yang， ZHANG Na. Fatigue Robustness and Lightweight Design of Driving Axle Housing for Heavy Truck [J]. Journal of Northeastern University Natural Science, 2019, 40(3): 365-369.
[12]	FENG Nai-shi， WANG Hong， HU Fo， LI Kang. Design and Analysis of Fiber-Reinforced Three-Cavity Structure of Soft Robot Hands [J]. Journal of Northeastern University Natural Science, 2019, 40(10): 1461-1466.
[13]	WU Qing-long， ZHOU Qi-cai， XIONG Xiao-lei， JIAO Hong-yu. Layout and Size Optimization Design of Tower Crane Boom Webs [J]. Journal of Northeastern University Natural Science, 2018, 39(9): 1309-1314.
[14]	SONG Bo， WANG Lian-guang， WANG Chun-gang. Stability Behavior of Channel Columns with Complex Edge Stiffeners and Cap Shaped Stiffeners [J]. Journal of Northeastern University Natural Science, 2018, 39(1): 143-147.
[15]	PAN Hong-gang， YUAN Hui-qun， ZHAO Tian-yu， WANG Guang-ding. Modal Testing Experiment Based on Simulation Impeller of Turbine [J]. Journal of Northeastern University Natural Science, 2017, 38(9): 1298-1303.