VISVESVARAYA TECHNOLOGICAL UNIVERSITY

BELAGAVI -590018

Seminar Report

On

“AIRLESS TYRES”

Submitted By

ADARSH GOWDA C M
USN: 4AD15ME004
Submitted in the partial fulfillment of the requirements for the award of degree
BACHELOR OF ENGINEERING
IN
MECHANICAL ENGINEERING
Under the guidance of
Dr. Rathnakar G
HOD & Professor

DEPARTMENT OF MECHANICAL ENGINEERING

ATME COLLEGE OF ENGINEERING
MYSURU -570028
 ATME COLLEGE OF ENGINEERING,MYSURU-028
(Affilatiated to Vishveswaraya Technology University,Belagavi)

DEPARTMENT OF MECHANICAL ENGINEERING

CERTIFICATE
This is to certify that the technical seminar work entitled “AIRLESS TYRES”is a
bonafide work carried out by ADARSH GOWDA C M bearing the USN 4AD15ME004 in
partial fulfillment of the reqirement or the award of Bachelor Degree in Mechanical Engineering
of Vishveswarya Technological University, Belgavi, during the academic year 2018-2019. This
report has been approved as it satisfies the academic requirements in respect of the “Technical
Seminar Work” prescribed for the degree.

Guide Head of the Department

Dr. Rathnakar G Dr. Rathnakar G

Professor Professor
Department of Mechanical Department of Mechanical
Engineering Engineering
 ACKNOWLEDGEMENT

The satisfaction that accompanies the successful completion of this technical seminar
work would be in complete without the mention of the people who made it possible, without
whose constant guidance and encouragement would have made efforts go in vain. I consider
myself privileged to express gratitude and respect towards all those who guided us through the
completion of this Technical Seminar Work.

I convey thanks to my project guide Dr. Rathnakar G of Mechanical Engineering

Department for providing encouragement, constant support and guidance which were of a great
help to complete this seminar report successfully.

I am grateful to Dr. Rathnakar G, Professor and Head of the Department Mechanical

Engineering for giving me the support and encouragement that was necessary for the completion
of this technical seminar.

ADARSH GOWDA C M

4AD15ME004

i
AIRLESS TYRES 2018-19

ABSTRACT

The Non Pneumatic Tyre (NPT) or Airless Tyre design was first developed by the French tyre
company Michelin. Its significant advantage over pneumatic tyres is that it does not use a
bladder full of compressed air and therefore it cannot burst or become flat. The inner hub of the
NPT connects to flexible polyurethane spokes which are used to support an outer rim and assume
the shock absorbing role of a traditional tyre’s pneumatic properties. Potential benefits of the
Non Pneumatic Tyre include the obvious safety and convenience of never having flat tyres.
Commercial applications will be in lower weight vehicles such as wheelchairs, scooters, heavy
vehicles like earth movers, military applications and NASA applied it in lunar rover. In future
NPT will replace traditional tyres which could avoid checking of tyre pressure, highway
blowouts and balancing between traction and comfort.

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CONTENTS Page no.

Chapter-1 Introduction 1

Chapter-2 History 2

Chapter-3 Airless Tyre 3

3.1 What Is Airless Tyre 4

3.2 How It Works 5

3.3 Different Design Approaches 6

3.3.1 NASA and the Apollo Lunar Rover 6

3.3.2 Michelin 7

3.3.3 Bridgestone 8

3.3.4 Resilient Technologies, LLC 9

3.2.5 SciTech 10

3.2.6 Hankook i-Flex 10

Chapter-4 Advantages And Disadvantages 12

4.1 Advantages of Airless tyres 12

4.2 Disadvantages of Airless tyres 13

Chapter-5 Applications Of Airless Tyres 14

Chapter-6 Safety And Environmental Concerns 16

6.1 Safety 16

6.2 Environmental Concerns 16

Conclusion 17

References 18

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LIST OF FIGURES Page no.

Figure 1. Concept of Airless tyre 4

Figure 2. Deformation of spokes 5

Figure 3. NASA'S Apollo Lunar Rover 6

Figure 4. Michelin 7

Figure 5. Bridgestone 8

Figure 6. Resilient Technologies 9

Figure 7. Hankook i-Flex 11

Figure 8. Riding lawn mowers 14

Figure 9. Backhoes 14

Figure 10. Military vehicle 15

Figure 11. All-terrain vehicle (ATV) 15

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Chapter-1

INTRODUCTION
For more than 100 years, vehicles have been rolling along on cushions of air encased in rubber.
Sometimes, we get so used to a certain product that no true changes are ever really made for
years, decades even. So begins an article discussing the development of airless tyres, something
that has become more prevalent in the past few years. A few tyre companies have started
experimenting with designs for non-pneumatic tyres including Michelin and Bridgestone, but
neither design has made it to mass production.

Creating a new non-pneumatic design for tyres has more positive implications than one might
think. For one thing, there are huge safety benefits. Having an airless tyre means there is no
possibility of a blowout, which in turn, means the number of highway accidents will but cut
significantly. Even for situations such as Humvees in the military, utilizing non-pneumatic tyres
has a great positive impact on safety. Tyres are the weak point in military vehicles and are often
targeted with explosives. If these vehicles used airless tyres, this would no longer be a concern.

There is also an environmental benefit to using this type of tyre. Since they never go flat and can
be retreaded, airless tyres will not have to be thrown away and replaced nearly as often as
pneumatic tyres. This will cut down landfill mass significantly.

Because of the benefits, I believe that it is extremely important that research and production of
airless tyres is continued and increased. This type of innovation works well in conjunction with
several engineering codes of ethics, and thus should be embraced by engineers everywhere. Cars
are things that people use every day, so any improvements over existing designs would affect the
lives of the majority of people. Learning about such a topic, therefore, I believe holds extreme
value- especially for us freshmen engineering students. In doing research into these kinds of
topics that hold significant meaning, we can see that what we will do can make a difference.

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Chapter-2

HISTORY
Going back in history, initially a craftsman known as wheel wright forged bands of iron & steel,
tying the wheel segments together as the metal contracted around the wheel. Hence the name,
tyre, as it tied the wheel together. This was then placed on wooden wheels of carts and wagons.

Explorers had seen Indians using sheets of rubber for waterproofing and in the 1800’s, Charles
Mcintosh was experimenting with this latex – sap from a tree in the Amazon. It had its problems
as the cold weather caused it to be brittle whilst in hot weather they became sticky. However, in
1839, Charles Goodyear discovered that by adding sulphur to the melted latex it gave elasticity
and strength. This vulcanized rubber was used to as cushion tyres for cycles.

John Dunlop, trying to make his son’s bicycle more comfortable to ride on, managed to invent
the pneumatic tyre. Another person, Robert Thomson, had already patented the idea of a
pneumatic rubber tyre so the Dunlop Rubber Company was established and won a legal battle
with Thomson. In 1891, the detachable pneumatic tyre was invented by two brothers, Michelin,
consisting of a tube bolted on to the rim.

In 1948, Michelin revealed the first radial tyre was developed and this was a revolutionary
achievement as it used steel-belted radial tyres. The advantages meant longer life and increased
mileage for the vehicle. However, it required a different suspension system and so was slowly
adopted. This was the tyre along with Dunlop’s invention, which gives us the tyre we have
today.

We have seen heavy tyre development, especially in motorsport, however we are yet to see
anything as revolutionary as previous key points in history. There have been concepts, with a
major one being the Michelin Tweel announced in 2005.

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Chapter-3

AIRLESS TYRE
Before the technology of airless tyres is discussed, it is important for the reader to understand
how standard pneumatic tyres function, and what advantages and disadvantages there are to
using them. A brief overview of the general concepts of airless tyres will then follow.

PNEUMATIC TYRES

The basic design of all pneumatic tyres is very similar, even though there are many different
types. They all include an inner core that holds pressurized air which is then covered with a layer
of rubber that comes in contact with the road, called a tread. The tread helps keep traction with
the road and prevents slipping and skidding. The tread has the tendency to wear down over time,
so if the tyre has not gone flat, a person will usually replace it at this point.

A main reason for using pneumatic tyres is the deformation that occurs during rotation. As the
tyre rolls, the weight of the car pushing down on it causes the tyre to flatten slightly. This, in
turn, causes the tyre to have a larger surface area to be in contact with the ground, which makes
for better traction. It also gives a slight cushioning effect, making running over small rocks or
debris unnoticeable. Or, as writer for How Stuff Works Ed Grabianowski puts it. If you’ve ever
taken a ride in an old-fashioned carriage with wooden wheels, you know what a difference a
pneumatic tyre makes.

Pneumatic tyres have their advantages, but they also have their disadvantages as well. The
possibility of a blowout or flat (when air is let out suddenly from the tyre) is a major concern
because they have the tendency to cause severe accidents. The task of regulating tyre pressure is
also a disadvantage because consumers are usually not very good at it. Although it may help with
traction to have the tyres a little flat, it comes at the price of handling. When there is not enough
air pressure in the tyre, the sidewalls flex causing the tyre to not quite follow the desired line of
steering. It is because of these disadvantages that tyre companies have taken an interest in
designing airless tyres.

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3.1 WHAT IS AIRLESS TYRE (TWEEL)?

Airless tyres or Non-pneumatic tyres (NPT), are the tyres that are not supported by air pressure.
These tyres are also called as Tweel which is a merger of the words tyre and wheel. This is
because the Tweel does not use a traditional wheel hub assembly. The Tweel concept was first
announced by Michelin back in 2005. It's structure is a solid inner hub mounted onto the vehicles
axle, that is surrounded by polyurethane spokes. This forms a pattern of wedges, which help to
absorb the impacts of the road. These spokes look similar to the ones found on bicycles and plays
the shock-absorbing role of the compressed air as in a traditional tyre. A sheer band is then
stretched across the spokes, which forms the outer edge of the tyre. It is the tension of the band
and the strength of the spokes that replaces the air pressure used on traditional tyres. When a
vehicle drives over an obstacle, a sleeping policeman for example, the tread and shear bands give
way as the spokes bend, before they quickly bounce back into shape.

Figure 1. Concept of Airless tyre

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3.2 HOW IT WORKS

The Airless tyre(Tweel) doesn’t use a traditional wheel hub assembly. A solid inner hub mounts
to the axle and is surrounded by polyurethane spokes arrayed in a pattern of wedges. A shear
band is stretched across the spokes, forming the outer edge of the tyre. On it sits the tread, the
part that comes in contact with the surface of the road. The cushion formed by the air trapped
inside a conventional tyre is replaced by the strength of the spokes, which receive the tension of
the shear band. Placed on the shear band is the tread, the part that makes contact with the surface
of the road. When the Tweel is running on the road, the spokes absorb road defects the same way
air pressure does in the case of pneumatic tyres. The flexible tread and shear bands deform
temporarily as the spokes bend, then quickly go back to the initial shape. Different spoke
tensions can be used, as required by the handling characteristics and lateral stiffness can also
vary. However, once produced the Tweel’s spoke tensions and lateral stiffness cannot be
adjusted.

Figure 2. Deformation of spokes

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3.3 DIFFERENT DESIGN APPROACHES

There are many different approaches to the design of the supports. This accounts for the main
differences between the overall designs of each company’s version of the airless tyre.

The following are approaches to making an airless tyre by different companies. Some solve more
problems than others, but it should be noted that all show an extreme amount of ingenuity that
may cross over into different types of engineering.

3.3.1 NASA and the Apollo Lunar Rover

The first major attempt at creating an airless tyre was in 1970 for NASA’s Apollo Lunar Roving
Vehicle. The tyres were made of steel strands woven together to form the shape, and then were
coated with zinc. In order to gain traction, titanium chevrons were added to the outer surface.

This design worked well on the moon, where comfort of the drivers was not an issue (i.e.
cushioning effect of pneumatic tyres), but it would not have been practical on earth. The design
would also be very expensive for a regular automobile, which is not attractive to the average
consumer.

Figure 3. NASA'S Apollo Lunar Rover

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3.3.2 Michelin
The next main attempt at creating an airless tyre was called the Tweel (combination of tyre and
wheel) by the tyre company, Michelin. Their design consisted of a thin rubber tread with V-
shaped spokes made of polyurethane.

There were extremely high hopes for this model when it came out. Columnist Don Sherman of
Car and Driver writes, introductory claims versus conventional pneumatic radials were two to
three times the tread life and five times higher lateral stiffness with only a slight increase in
rolling resistance. This development has very positive implications because it means that the tyre
would last about two times longer than a standard pneumatic tyre before it would have to be
retreaded. The only major problem with this model is at highway speeds, the spokes tend to
vibrate, causing excessive noise.

When asked about recent developments for the Tweel, Michelin refused comment, either because
they dropped the project, are working with the military, or do not want to divulge findings to
their competitors.

Figure 4. Michelin

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3.3.3 Bridgestone
Another model for the non-pneumatic tyre came from the well-known tyre company,
Bridgestone. Although very similar in concept to Michelin’s Tweel, there are some key
differences.

The core is made of rigid aluminum and has thermoplastic spokes radiating outward at an angle
in opposite directions on each side. This creates more stability and less lateral movement in the
tyre. Bridgestone also fixed the vibration and noise problem in this way as well. The main issue
with their design was that debris had the tendency to get caught in the gaps between spokes. In
addition, the materials used in the tyres are recyclable, contributing to the efficient use of
resources. Further, by pursuing extremely low rolling resistance and contributing to reductions in
CO2 emissions through use of proprietary technologies, Bridgestone believes it is possible to
achieve even higher levels of environmental friendliness and safety. Bridgestone is pursuing this
technological development with the aim of achieving a "cradle to cradle" process that proactively
maximizes the cyclical use of resources from worn tyres into new tyres and the use of recyclable
resources.

Figure 5. Bridgestone

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3.3.4 Resilient Technologies, LLC

As stated before, the production of airless tyres would be extremely beneficial to the military.
The group Resilient Technologies, LLC is working with the military to develop such a tyre for
Humvees. To meet the requirements of heavy loads and rough terrain, these tyres are quite
industrial-looking. They consist of a thick outer tread with a honeycomb-like structure inside.
This allows for the load to be evenly distributed around the tyre.

The honeycomb design could be adjusted for any application where loss of air pressure causes
problems, where tyres face numerous hazards on a regular basis or where business want to
reduce downtime for tyre issues and maintenance, such as agricultural and construction
equipment.

This design causes the tyre to be very load, making in unsuitable for regular automobiles. For
military purposes however, it is useful. It can withstand a large amount of abuse, including blasts
when under attack.

Figure 6. Resilient Technologies, LLC

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3.2.5 SciTech
The most convenient design for everyday vehicles comes from a company called SciTech. Their
tyre fits on standard rims, unlike all previously mentioned models (which are really a
combination of a wheel and a tyre), and has the look of a regular pneumatic tyre form the
outside. Instead of supports radiating from the center, their supports are spring-like. There are a
hundred supports in every tyre and nine are in contact with the road at any one time. There is
also a secondary support system in order to distribute load to all of the supports which have 550
pounds of strength each and are made of a thermoplastic glass fiber composite material.

Because SciTech’s tyre has closed sidewalls and no spokes, there is no noise or overheating
issue as well as no problems with debris. A division of SciTech Industries, has announced a
successful test of the company’s non-pneumatic airless tyre at an industry laboratory in Ohio.
The company says the tyre achieved a cool and uniform 10-hour run at highway speed at
passenger car load. Mounted on a standard rim with a conventional tyre mounting machine, the
airless tyre is self-supporting, with internal glass fiber composite ribs supporting the load. Built
and cured in a conventional steam-bladder mold at a commercial tyre factory, the composite rib
and tyre construction are covered by world wide patents.

3.2.6 Hankook i-Flex

A futuristic design concept, the Hankook i-Flex is an airless wheel and tyre, all in one. Aiming to
keep losses to a minimum when converting energy, HankookTyres engineers have
reconceptualised the automobile tyre. With the HankookTyres i-Flex, the company presents the
prototype of a non-pneumatic tyre that will help increase the overall efficiency of vehicles
thereby improving their energy balance.

With 95 percent of its construction being recyclable, the Hankook i-Flex is made from
polyurethane synthetics, with the tyre manufactured in conjunction with its rim as one unit. It is
considerably lighter than conventional wheel-tyre combinations and does not require air like
conventional pneumatic tyres, able to offer shock absorbency through the unique design. Fuel
consumption and noise emissions are thus optimized while simultaneously increasing vehicle
safety.

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Displayed at the Frankfurt show on an ABT-tuned Volkswagen Up, the Hankook i-Flex tyre
specification is 155/590 14 (155mm wide, 590mm diameter, 14-inch ‘simulated wheel
size). Through HankookTyres hands-on display and video guides, visitors to the Frankfurt show
can alter the colours of the Hankook i-Flex.

At the 65th IAA (International Automobile-Ausstellung), September 12-22, in Frankfurt,

premium tyre manufacturer HankookTyre will present its latest innovations, production-ready
prototypes and trend-setting tyre concepts designed to meet the demands of future mobility, in
Hall 8, Stand 24.

Figure 7. Hankook i-Flex

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Chapter-4

ADVANTAGES AND DISADVANTAGES OF AIRLESS

TYRES

4.1 Advantages of Airless tyres

 Eliminates air leaks or tyre blow outs.

 With no air pressure you are left with consistent economy and handling.
 Its flexibility provides an increase in surface area of contact.
 No maintenance needed.
 To lengthen tread life.
 Facilitate recycling.
 Makes Vehicle more Efficient have high lateral strength for better handling without a
loss in comfort.
 Vehicle remains under control even in emergency brake.
 Remains mobile even with some of the spokes damaged or missing.
 Durability & Long Life.
 Can take gunfire or explosion.
 Less environmental impact.

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4.2 Disadvantages of Airless tyres

 Lack of adjustability

One of the biggest disadvantages of the Tweel is that once it has been manufactured, it cannot be
adjusted. In this case if the car needed a different kind of setting, a whole new set of Tweels will
be required. On the plus side Tweels are made with five times the lateral stiffness compared to
pneumatic tyres, enabling very responsive handling.

 Not as economic as pneumatic tyres

Michelin are currently working on enabling the Tweels to be as fuel efficient as pneumatic tyres.
Currently they are within 5% of the rolling resistance and mass levels.

 Vibration

This could be one of the Tweels biggest downsides. Vibrations become considerate once a
vehicle is driving above 50 mph, while causing a lot of noise. Also disturbing is the amount of
heat the Tweels generate. Long distance journey with tweels would be very unpleasant unless
these areas are improved upon.

 Different Manufacturing process

Another problem is that creating airless tyres requires a totally different manufacturing process.
At this point of time, the tyre industry revolves around the manufacture of traditional pneumatic
tyres. To modify factories and service equipment would be a major change, and the facilities just
don’t exist yet.

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Chapter-5

APPLICATIONS OF AIRLESS TYRES

1. They are used on some small vehicles such as riding lawn mowers and motorized golf
carts.

Figure 8. Riding lawn mowers

2. They are also used on heavy equipment such as backhoes, which are required to operate
on sites such as building demolition.

Figure 9. Backhoes

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3. Military Usage Tweel deflects mine blasts away from the vehicle better than standard
tyres and that the Tweel remains mobile even with some of the spokes damaged or
missing.

Figure 10. Military vehicle

4. The airless tyres are also used in All-terrain vehicle(ATV) made by Polaris. These tyres
can suffer a shot from a .50-caliber rifle and still travel 350 miles, and also drive 1,000
miles after running over a railroad spike. It will start at $14,999.

Figure 11. All-terrain vehicle

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Chapter-6

SAFETY AND ENVIRONMENTAL CONCERNS

6.1 Safety
As stated before, the main danger of pneumatic tyres is the chance of a flat or blowout that
usually occurs at highway speeds. A blowout is when a tyre basically pops and deflates rapidly.
This causes the driver to lose control of the car and risk the possibility of hitting another vehicle.
With airless tyres, this is no longer an issue. There is no chance for a blowout, and the driver
does not have to be concerned about changing a flat (also eliminates the need for a spare
tyre).The assurance of never having a flat tyre is also beneficial in areas such as construction,
where there can be sharp debris, and in the military. It is especially useful in the military because
the tyres of Humvees are often targeted when under attack, as they are the weakest part of the
vehicle. If the tyres are blown, the vehicle cannot go anywhere. Airless tyres in this sense can
save the lives of troops riding in Humvees because the tyres can take more abuse.

Better handling is also a benefit when it comes to safety. Although it does not vary by much, it is
important to have that extra stability in the tyre to make the car go exactly in the direction in
which it is steered. This is especially helpful in swerving to avoid an obstacle such as an animal
or another car. So for this reason, improved handling is not just for a better driving experience.

6.2 Environmental Concerns

Non-pneumatic tyres are also expected to have a positive environmental impact. As of now, tyre
companies must address the growing mountain of bald tyres defiling the landscape and find a
way to recycle or find something that lasts longer and can be recycled. In the case of airless
tyres, it can be the latter. SciTech’s airless tyre is said to be able to outlast the car. This has
enormous environmental implications because with so many cars on the road, there are many old
tyres that have to be disposed of. Because airless tyres mostly use composite materials, there is
only a small amount of rubber that actually goes into it. Also, since the tread life of most models
is longer than that of pneumatic tyres, the rubber does not have to be replaced very often. This
means that there will be less of it to dispose of later.

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CONCLUSION
Tyres may seem to be a trivial part of an automobile that cannot be improved, but research into
airless tyres shows otherwise. This new technology will increase the safety of cars as well as
have a positive impact environmentally. Since these tyres are also able to be retreaded, there is
the possibility of a smaller cost per tyre- which is always embraced by the consumer. This
innovative project is also backed and guided by engineering codes of ethics which will ensure
that the development is conducted in a way that it responsible and fair.

It is also important to think about the implications of a technology such as this. This is
reinventing the wheel in a way! If engineers can do this, they will think about other things that
can be improved. Then we will not only have inventors of entirely new technologies, but also
people who can take something already in place and make it even better. This type of innovation
will become increasingly valuable in the future which is why researching topics such as this is
very important for young people. It gives them a sense of what they can do after all of their hard-
working years of schooling and that what they can do will matter.

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REFERENCES
1. A.Kwon. (2012) Design Spotlight: The Airless Tyre. Gear Patrol (Online article)
http://gearpatrol.com/2012/05/24/design-spotlight-the-airless-tyre/ p. 1

2. E.Grabianowski. (2011). How the Tweel Airless Tyre Works How Stuff Works (Online article)
http://auto.howstuffworks.com/tweel-airless-tyre.htm p. 2

3. D.Sherman. (2012). Tech Dept.: The Latest on the Airless Tyre-and-Wheel Combo Car and
Driver (Online article) http://www.caranddriver.com/features/tech-dept-the-latest-on-the-airless-
tyre-and-wheel-combo-tech-dept p. 1

4. B.Mattmiller. (2008). Airless Tyre Project May Prove a Lifesaver in Military Combat.
University of Wisconsin News Archive (Online
article).http://www.engr.wisc.edu/news/archive/2008/Jul08.html p. 1

5. Airless Tyre Project SciTech Industries (2012). (Video)http://vimeo.com/41741265

6. Goodyear’s Prototype Non-pneumatic Lunar Tyre Unexplained-Mysteries.com (Online article)

http://www.unexplained-mysteries.com/forum/index.php?showtopic=69787&st=150

7. M. Mazzoni (2011). Bridgestone Debuts Airless Car Tyre Earth911.com (Online article)
http://earth911.com/news/2011/12/06/bridgestone-debuts-airless-car-tyre/

8. http://curiosity.discovery.com/question/downside-with-tweel-airless-tyres

9. Kwame Opam on November 18, 2013http://www.theverge.com/2013/11/18/5117710/polaris-

latest-atv-has-airless-tyres-that-can-withstand-50-caliber

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