Comparative Analysis of Steel Wheel Rim & Alloy Wheel Rim of a Car with Respective Materials

Abstract

This project conducts a comparative analysis of steel and alloy wheel rims for the Maruti Suzuki Baleno Sigma and Alpha variants. The aim is to assess the performance and suitability of these rim types for the specific vehicle models. Through a systematic examination of design considerations, structural analysis, and overall performance evaluation, the project provides valuable insights into the characteristics and capabilities of Carbon steel and Aluminium alloy wheel rims. CAD modeling, finite element analysis (FEA), and performance assessment techniques are employed to analyze stress distribution, strain levels, and deformation patterns. By understanding the differences and performance attributes of steel and alloy rims, the project assists in enhancing the overall performance and aesthetics of the vehicles.

Introduction

I. INTRODUCTION

The selection of wheel rims for automobiles is a critical decision, as it significantly influences the vehicle's performance, safety, and aesthetics. Two popular options in the market are steel wheel rims and alloy wheel rims. While steel rims have traditionally been used for their durability and cost-effectiveness, alloy rims offer advantages in terms of weight reduction, improved fuel efficiency, and enhanced styling options. This project gives comparative analysis between steel wheel rims and alloy wheel rims.

The study involves a detailed examination of their design considerations, static structural analysis, Dynamic stress analysis , Modal analysis and harmonic response. The focus is on studying and analyzing the steel wheel rim and alloy wheel rim used in the Maruti Suzuki Baleno Sigma and Alpha variants. CAD modeling software, such as Creo Parametric, is utilized to create accurate 3D models of representative steel and alloy wheel rims. Finite Element Analysis (FEA) employed using ANSYS Workbench to simulate the structural behavior of the rims under various loading conditions.

Additionally, harmonic response and vibration analysis is carried out to study the dynamic behavior and potential resonant frequencies of the rims.Furthermore, a study on the fatigue life of both types of rims will be conducted, considering cyclic loading, material properties, and stress distribution. This investigation estimates the expected fatigue life and assesses the durability of the rims under typical operating conditions.

II. MATERIAL SELECTION

A. Compositions

1. Alloy Wheel Rims

a. Aluminum: Typically 90-95%

b. Magnesium: Typically 2-5%

c. Silicon: Typically 1-3%

d. Other metals: Typically 1-2% (such as copper, nickel, and zinc).

2.  Steel Wheel Rims

a. Iron: Typically 97-99%

b. Carbon: Typically 0.2-0.5%

c. Manganese: Typically 0.5-1.2%

d. Other metals: Typically 0.2-0.5% (such as chromium, nickel, and copper)

The alloy compositions play a significant role in determining the material properties and performance characteristics of the wheel rims. Alloy wheel rims, with their aluminum-magnesium-silicon composition, offer lightweight properties, good corrosion resistance, and improved heat dissipation. The addition of other metals helps enhance specific properties such as strength and durability.

Steel wheel rims, primarily composed of iron with carbon, manganese, and other alloying elements, provide high tensile strength, excellent impact resistance, and durability. The carbon content contributes to the hardness and strength of the steel rims. It's important to note that the specific alloy compositions can vary based on the manufacturer and their proprietary formulations.

B. Comparison

1. Steel Wheel Rims

a. Advantages

• Durability: Steel wheel rims are known for their strength and durability, making them suitable for heavy-duty applications and rough terrains.
• Affordability: Steel wheel rims are generally more affordable compared to alloy rims, making them a cost-effective option for vehicle owners.

b. Disadvantages

• Weight: Steel wheel rims are heavier compared to alloy rims, which can affect the overall weight of the vehicle and fuel efficiency.
• Corrosion: Steel rims are prone to corrosion, especially in regions with high humidity or salted roads, requiring regular maintenance and protection to prevent rusting.

c. Performance Metrics

• Tensile Strength: Steel wheel rims have higher tensile strength, providing excellent load-carrying capacity
• Impact Resistance: Steel rims offer superior impact resistance, making them suitable for off-road or rugged driving conditions.
• Stiffness: Steel rims have a higher modulus of elasticity, resulting in stiffer overall wheel assemblies.

2. Alloy Wheel Rims

a. Advantages

• Lightweight: Alloy wheel rims are significantly lighter than steel rims, improving the vehicle's overall performance, handling, and fuel efficiency.
• Aesthetics: Alloy rims offer a wide range of stylish designs and finishes, enhancing the appearance of the vehicle.
• Corrosion Resistance: Alloy rims are more resistant to corrosion compared to steel rims, requiring less maintenance and providing longer-lasting aesthetics.

b. Disadvantages

• Cost: Alloy wheel rims tend to be more expensive than steel rims due to the higher cost of materials and manufacturing processes.
• Vulnerability to Damage: Alloy rims are more susceptible to damage from impacts and potholes compared to steel rims.

c. Performance Metrics

• Weight Reduction: Alloy rims contribute to reducing the unsprung weight of the vehicle, leading to improved handling and suspension response.
• Heat Dissipation: Alloy rims offer better heat dissipation compared to steel rims, reducing the risk of brake fade during prolonged braking.

III. DESIGN AND MODELING

A. CREO

Creo is a family of Computer-aided design (CAD) apps supporting product design for discrete manufacturers and is developed by PTC. The suite consists of apps, each delivering a distinct set of capabilities for a user role within product development. Creo runs on Microsoft Windows and provides apps for 3D CAD parametric feature solid modeling, 3D direct modeling, 2D orthographic views, Finite Element Analysis and simulation, schematic design, technical illustrations, and viewing and visualization. Creo can also be paired with Mastercam (Machining based software) to machine any designed model in a minimal timeframe

B. ANSYS

For doing analysis of the model created in CREO PARAMETRIC, we used the finite element solver ANSYS 19.1. ANSYS is a general purpose finite element analysis (FEA) software package. Finite Element Analysis is a numerical method of deconstructing a complex system into very small pieces (of user-designated size) called elements. The software implements equations that govern the behavior of these elements and solve them all creating a comprehensive explanation of how the system acts as a whole. These results then can be presented in tabular or graphical forms.

This type of analysis is typically used for design and optimization of a system that is too complex to analyze by hand. Systems that may fit into this category are too complex due to their geometry, scale, or governing equations. ANSYS is the standard FEA teaching tool within mechanical engineering.

Conclusion

A comprehensive parametric modeling using Creo was conducted on both carbon steel and aluminum alloy wheel rims, followed by various analyses performed in ANSYS. A force of 625N was applied to assess the stress and strain values. 1) The deformation levels differed for each wheel rim at varying frequencies, with the alloy wheel rim exhibiting higher stability compared to the steel wheel rim. 2) To further evaluate the structural behavior, a vibrational analysis was carried out. The harmonic response analysis indicated a maximum amplitude of 1.6893, suggesting a stable model. 3) These findings indicate that the aluminum wheel rim outperforms the steel wheel rim in terms of heat dissipation, braking performance, and fatigue life. 4) The results strongly suggest that the aluminum alloy wheel rim is more suitable for the intended application due to its superior stability under vibrational loads, enhanced heat dissipation capabilities, improved braking performance, and extended fatigue life. These factors contribute to its overall superiority over the carbon steel wheel rim Further research can be conducted to develop advance aluminum alloys with enhanced mechanical properties,this coil dinvolve exploring novel alloy compositions or incorporating reinforced elements to optimize the material performance.

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Copyright

Copyright © 2023 Monika Khawaskar , Dr. Prashanth Dhutekar. This is an open access article distributed under the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.