International Journal of Advanced Science and Technology

Vol. 29, No. 3s, (2020), pp. 2078 - 2085

Cornering Fatigue Test and Radial Fatigue Test on a Rim with

steps for a Mono-tyre E-Vehicle using Finite Element Analysis

Akash Sah1*, Dr. Pradeep V. Jadhav2, Manoranjan Singh3

1
P.G. Scholar, Dept. of Mechanical Engg., BVDUCOE, Pune-411046, India
2
Professor, Dept. of Mechanical Engg., BVDUCOE, Pune-411046, India
3
P.G. Scholar, Dept. of Mechanical Engg., BVDUCOE, Pune-411046, India
1
[email protected] , [email protected] , [email protected]

Abstract
The wheel rim being critical component in the Monotyre E-vehicle has to meet strict
requirements of driving safety. Also, it should support the visual appearance and required
engineering functions. The wheel rim also must withstand the various loading
environments. To achieve better performance and quality, a number of tests (rotating
bending test, radial fatigue test, and rim impact test) are done by producers and designers
to insure it meets the standards. The wheel rim tests are much expensive and consume lot
of time. Computer simulation and Finite Element analysis of these tests can reduce the
time and cost required to perform a wheel rim design at significant level. In this paper we
discussed the Finite Element Analysis of wheel rim using Cornering Fatigue test [CFT]
and Radial Fatigue test [RFT].

Keywords: Rim Steps, Monowheel Configuration, Magnesium Alloy, CFT, RFT.

1. Introduction
The tyre works as a complete wheel only after it is installed on the rim and is inflated with
a certain amount of pressurized gas. Therefore, the tyre and wheel assembly influence the
function and the performance of the vehicle. The tyre is designed and manufactured to
suit a standard rim and once installed on the correct rim the tyre will perform up to its
desired level.
The flange is a part of rim, which holds the both beads of the tyre. Bead seat comes in
contact with the bead face and is a part of rim, which holds the tyre in a radial direction
[1].
Magnesium Alloy Wheel is approximately 30% lighter than aluminium, having Modulus
of elasticity as 44 GPa and also, excellent as in for size stability and impact resistance.
Objective of the project is to find the total deformation of newly designed Magnesium
alloy wheel rim due to static loads. The project mainly involves in modeling of the wheel
using SOLIDWORKS and the analysis is performed on the modelled component using
ANSYS. Analysis that is performed here typically includes Structural Analysis and Radial
Fatigue Analysis.
The rim was combined with the steps in the inside part so as to provide extra strength and
absorb the stresses during fatigue loading conditions. Also, it is a special-purpose rim
with no spokes for out-runner type electric mobility vehicles such as Monotyre bike.
The rim is to carry all the components of the bike inside the rim hub as well as the weight
of the rider combined with the weight of the frame.

ISSN: 2005-4238 IJAST 2078

Copyright ⓒ 2020 SERSC
 International Journal of Advanced Science and Technology
Vol. 29, No. 3s, (2020), pp. 2078 - 2085

2. SET-UP EQUIPMENT FOR FATIGUE TESTING

The Radial Fatigue test machine [2] (Figure 1.) has been studied so as to understand the
testing procedure and how the results can be simulated on a software. The machine is
followed so that there is an ease of applying the loads and providing the boundary
conditions in the pre-processor stage of analysis. The solutions along with the meshing
and modeling gained from the tests are discussed in this paper.

Figure 1. Model equipment for Radial Fatigue testing

3. OBECTIVES AND METHODOLOGY

Wheels have one of foremost importance in safe running of a vehicle (Mono-tyre
bike in this particular case). The main objectives are to simulate the Cornering
Fatigue analysis and Radial Fatigue analysis. To perform the analysis and confirm
the objectives, a certain methodology is followed to carry out optimization and
studying the performance of the particular component. There are two methods
mainly used in design analysis, which is reverse engineering and finite element
analysis [3]. Reverse engineering is a good approach of discovering the
technological principle of any new machine. The finite element analysis, on the
other hand is an approach to discretely study the effects of loading and provide with
necessary optimization in design.
The material for rim has been taken as Magnesium alloy whereas the material for the
steps has been taken as EN8.

4. FINITE ELEMENT ANALYSIS OF WHEEL

4.1. Solid modeling of Rim and Steps
The 3D models of the Rim and Steps were created in SOLIDWORKS, the
drafting package and the same was then assembled and converted to “.stp” (STEP
203) format, which is then translated and exported to ANSYS, the finite element
package.

(a) (b) (c)

Figure 2. Solid model of the (a)rim, (b)steps and (c)wheel rim
assembly

ISSN: 2005-4238 IJAST 2079

Copyright ⓒ 2020 SERSC
 International Journal of Advanced Science and Technology
Vol. 29, No. 3s, (2020), pp. 2078 - 2085

The software then, automatically generates the 3D model (Figure. 2) in the pre-
processor environment where meshing and set-up for solution was done.

4.2. Meshing:

Figure 3. Mesh of wheel rim for Cornering Fatigue Test (CFT)

While meshing for CFT (Figure 3), the Hex-Dominant method was used, where
the elements were found out to be 154931 and nodes to be 647460, whereas for RFT
(Figure 4), the Patch conforming method with Quad/tri elements was used and had
44136 elements and 132843 nodes.

Fig 4. Meshing of rim for Radial Fatigue Test (RFT)

At the critical areas such as the junction of steps and rim, face meshing has been
done and an element size of 3 mm was given to ensure the proper discretization of
the elements for both CFT and RFT.

4.2.1 Material Selection: Magnesium Alloy Wheel is about 30% lighter than
Aluminium alloy wheel, having Modulus of elasticity as 44 GPa (Table 1. Properties
comparison of Aluminium alloy & Magnesium alloy) and also, excellent as in for
size stability and impact resistance.

ISSN: 2005-4238 IJAST 2080

Copyright ⓒ 2020 SERSC
 International Journal of Advanced Science and Technology
Vol. 29, No. 3s, (2020), pp. 2078 - 2085

Table 1. Properties comparison of Aluminium alloy & Magnesium

alloy
Properties Desirable choice Aluminium alloy Magnesium alloy
Elasticity modulus
Lower is better 72 44
(N/m 2)
Poisson’s Ration Lower is better 0.33 0.35

Mass Density (kg/m3) Lower is better 2800 1700

Tensile Strength
Higher is better 273 425
(MPa)
Yield Strength (MPa) Higher is better 225 382
Thermal Expansion
Lower is better 1.9e-005 1.9e-005
Coefficient(K -1 )
Specific Heat J/(kgK) Lower is better 963 1000

4.2.2 Boundary condition: A pressure of 0.207 N/mm 2 is applied on the exterior

ring surface of the rim. The same surface is also constrained in all degrees of
freedom, shown in figure 5.

Fig 5. Applied boundary condition on rim

4.2.3 Loading Condition: Here the load of 1500 N is applied throughout the
inner ring surface of the rim diameter.

4.2.4 Load calculations:

Weight of the bike(approx.) = 50 kg
Weight of passenger(maximum) = 90 kg
Weight of luggage = 10 kg
Total load = 150 kg
Total weight = 1500 N

4.2.5 Pressure due to inflation:

Considering 30 psi of air pressure load acting on the exterior ring surface of the
wheel. Therefore,
30 = 30 x 0.4535 x 9.81/ (25.4) 2 = 0.207 N/mm 2

ISSN: 2005-4238 IJAST 2081

Copyright ⓒ 2020 SERSC
 International Journal of Advanced Science and Technology
Vol. 29, No. 3s, (2020), pp. 2078 - 2085

5. RESULTS AND DISCUSSION

The total weight of the vehicle is balanced with vertical reaction force from the road
through the tyre. This load constantly compresses the wheel radially. While the vehicle is
running, the radial load becomes a cyclic load with the rotation of the wheel.
Therefore, Radial loading is a vital performance characteristic that needs to be evaluated
before going into actual loading conditions.
On the other side, CFT is all about dynamic loading experienced on the outer flange of
the rim while in rotation.
The FEA results of wheel rim has been tabulated for CFT and RFT (Table 2: Results after
CFT and RFT). The analyses results show that the Equivalent stresses (von-mises) and
Shear stress are within the permissible limits of the material and the structure deforms
slightly at 1500 N of force. The total deformation shows that the structure can stand the
load but should be considered for redesigning as well as re-selection of the material.

Table 2. Results after CFT and RFT

Cornering Fatigue Test Radial Fatigue Test

Result parameter Unit
Allowed range Result Allowed range Result
Equivalent elastic
1.3e-6 1.242e-6 2e-6 1.04e-6 mm/mm
strain
Maximum shear
10e-7 9.647e-7 1.8e-6 1.6e-6 mm/mm
elastic strain
Equivalent stress 0.2 0.137 0.1 0.045 MPa
Maximum shear
0.15 0.074 0.15 0.027 MPa
stress
Total
4e-5 3.33e-5 2.70e-5 2.54e-5 mm
Deformation

Figure 6. Equivalent elastic strain under CFT and RFT

The equivalent elastic strain under CFT and RFT is shown in above Figure 6. The results
show that cornering strain is much lesser than the radial strain.

Figure 7. Maximum Shear Elastic Strain under CFT and RFT

ISSN: 2005-4238 IJAST 2082

Copyright ⓒ 2020 SERSC
 International Journal of Advanced Science and Technology
Vol. 29, No. 3s, (2020), pp. 2078 - 2085

The maximum shear elastic strain under CFT and RFT is shown in above Figure 7. The
results show that cornering shear elastic strain is much higher than the radial shear elastic
strain.

Figure 8. Equivalent Stress under CFT and RFT

The equivalent stress under CFT and RFT is shown in above Figure 8. The results show
that cornering stress is more than the radial stress.

Figure 9. Maximum Shear Stress under CFT and RFT

The maximum shear stress under CFT and RFT is shown in above Figure 9. The results
show that cornering shear stress is more than the radial shear stress.

Figure 10. Total deformation under CFT and RFT

The total deformation under CFT and RFT is shown in above figure 7. The results show
that cornering deformation is much greater than the radial deformation.

6. Conclusions

Cornering fatigue analysis shows that the rim profile can sustain loads up to 1500 N with
minimum deformation and elastic strain, within permissible limits.
Radial Fatigue analysis shows that under radial loading the rim with steps can easily
sustain radial loads up to 1500 N with minimum deformation, stresses and elastic strain,
within permissible limits.

ISSN: 2005-4238 IJAST 2083

Copyright ⓒ 2020 SERSC
 International Journal of Advanced Science and Technology
Vol. 29, No. 3s, (2020), pp. 2078 - 2085

Weight reduction is achieved by using Magnesium alloy material that reduces weight up
to 60% than the original design which was made using Aluminium alloy (AlSi12)
material.
This rim with steps is fit for e-vehicle and can be used for E-vehicle application but is
limited up to a loading of 1500 N only and can be further improved for higher load
values.

7. Acknowledgement
I express my sincere gratitude to worthy Principal, Bharati Vidyapeeth (Deemed
to be University) College of Engineering, Pune. I am also thankful to respected
HOD, Mechanical Engineering, BVDUCOE, Pune for allowing me to carry out the
work.
Lastly, I would like to thank my parents for their continuous moral support and
encouragement.

8. References
8.1. Journal Article
[1] S. Chaitanya, B. V. Ramana Murty “Mass optimization of automobile wheel rim”, IJETT, VOL. 26,
Number 3, August 2015.
[2] Mr. Sushant K. Bawne, Prof. Y. L. Yenkar. “Optimization of car rim”, IJERA, ISSN: 2248-9622, VOL.5,
Issue 10, October 2015.
[3] Angel Bhattacharjya “Finite Element Analysis of Wheel Hub for Cornering and Radial Load Condition”,
in press.
[4] Eilam, Eldad & Chikofsky, Elliot J., (2007). “Reversing Secrets of reverse Engineering”, John Wiley &
Sons. P.3.ISBN9780764574818.
[5] M. Saran Theja, M. Vamsi Krishna “Structural and Fatigue Analysis of Two-Wheeler Light Weight Alloy
Wheel”, IOSR Journal of Mechanical and Civil Engineering (IOSR-JMCE) e-ISSN: 2278-1684 p-ISSN:
2320
[6] J. Janardhan, V. Ravi Kumar, R. Lalitha Narayana “Radial Fatigue Analysis of An Alloy Wheel”, Int.
Journal of Engineering Research and Applications www.ijera.com ISSN : 2248-9622, Vol. 4, Issue 12(
Part 6), December 2014, pp.253-258.

8.2. Chapter in a Book

[7] ENGINEERING FOR RURAL DEVELOPMENT, Jelgava, 24.-26.05.2017 “MECHANICAL
PROPERTIES OF AlSi12 ALLOY WITH ALUMINIUM BRONZE”; Tomasz Lipinski; University of
Warmia and Mazury in Olsztyn, Poland.

8.3. Conference Proceedings

[8] Rakesh B. Thakare “Stress Analysis in Wheel Rim by using Dynamic Cornering Fatigue Test Under
Different Conditions” Vol-3 Issue-2 2017 IJARIIE-ISSN (O)-2395-4396.
[9] Akash Sah, Pradeep. V. Jadhav “Linear static analysis and dynamic analysis of a mono-tyre bike wheel
inner-hub design using finite element analysis”, unpublished.

ISSN: 2005-4238 IJAST 2084

Copyright ⓒ 2020 SERSC
 International Journal of Advanced Science and Technology
Vol. 29, No. 3s, (2020), pp. 2078 - 2085

Authors

Akash Sah, P.G. Scholar, Department of Mechanical Engineering,

Bharati Vidyapeeth Deemed University, Katraj, Pune- 411046, India.

Dr. Pradeep V. Jadhav, Professor, Department of Mechanical

Engineering, Bharati Vidyapeeth Deemed University, Katraj, Pune- 411046, India.

Manoranjan Singh, P.G. Scholar, Department of Mechanical

Engineering, Bharati Vidyapeeth Deemed University, Katraj, Pune- 411046, India.

ISSN: 2005-4238 IJAST 2085

Copyright ⓒ 2020 SERSC