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AbstractThe essence of car wheel rim provides a firm base on which to fit the tire. Its
dimensions, shape should be suitable to adequately accommodate the particular
tire required for the vehicle. In this project a tire of car wheel rim belonging to
the disc wheel category is considered. Design is an important industrial activity
which influences the quality of the product. The wheel rim is modeled by using
modeling software catiav5r20. By using this software the time spent in producing
the complex 3- D models and the risk involved in the design and manufacturing
process can be easily minimized. So the modeling of the wheel rim is made by
using CATIA
In recent years, competition in the automobile market is getting increase with
restpect to fuel economy, especially for the light commercial vehicles. Moreover,
there is a significant necessity about reducing fuel consumption level for
automobile companies. The weight of a vehicle is one of the most important
factor that affecting the fuel economy. The weight minimization of wheel has
more effective than the weight minimization of elsewhere in a vehicle due to the
rotational moment of inertia effect during motion. Therefore, the wheel design
should be optimized by considering fundamental attributes of a light commercial
vehicle such as NVH, Durability and Weight.
After completing the design of rim in catia v5 part design workbench, assembly
is done using assembly workbench for rim and tyre.
Design work is done under required dimension and assembled in assembly
workbench using constrain tools.
INTRODUCTION
I. INTRODUCTION
Archaeologies and historians of today see the introduction of the wheel as
the real genesis of any old civilization. The wheel is the most significant discovery of old
times. The Wheel has developed from an oversized bearing to a fully integral part of any
modern transportation vehicle. The modern motor vehicles are produced according to very
strict Rules to ensure the safety of passengers.
In recent years, the procedures have been improved by a variety of
experimental and analytical methods for structural analysis (finite element method). Within
the past 10 years, durability analysis (fatigue life predication) and reliability method for
dealing with variation inherent in engineering structure have been applied to the automotive
wheel Braking performance shows effect on the wheel rim parameters: size, weight, design
and Materials.
The size of the wheel rim governs how much space there is between the rim and
brake rotor. If the diameter of the wheel rim is higher there will be more scope for air flow
around the brakes and therefore better cooling. The weight of the wheel rim is also an
important issue .The handling of a vehicle is always improved with light weight. The
rotational inertia is also obvious factor goes up with more weights as well, causing even more
work for the brakes.
Another factor in handling has to do with wheel strength and flex. A more rigid
wheel will reduce wheel flex. This is essentially important with low aspect ratio, high
performance tires that can be generate high cornering forces. Car wheels are classified in to
two main groups, steel wheels and alloy wheels. Alloy wheels are frequently fitted typical
During the manufacturing of modern vehicles. All steel wheels to be made up of two pressed
components, the rim and the wheel disc, which are welded together.
8. Well: This is a part of rim with depth and width to facilitate tire mounting and removal
from the rim.
CHAPTER-2
2.1Types of Wheel Rims:
2.1.1 According to Shape of Rim
Typical rim shape vehicles are made up of the following.
a) Drop centre rim (DC)
Drop centre rim (DC rim) is shaped so there is fine between
the bead seat parts which is placed on both sides of the rim. This is to make the
mounting and dismounting of the tire easy. In most circumstances there is a
taper of 5 degrees in the bead seat area.
rim is mostly applied to low aspect ratio tires. This design is presently applied to
rims for tires of most passenger vehicles.
c) Wide Drop Centre Rim with Hum :In addition, this design has a bump, on
the beginning of the bead seat area. This hump is to prevent the bead sliding
down and air outflow from the rim due to the horizontal force applied to the tire
when a vehicle tubeless tires runs at high speed.
recent years, is explained here. The manufacturing method for the light alloy wheel is
classified into two. They are cast metal or the forged manufacturing methods.
The aluminum alloy wheel is manufactured both ways, and the casting
manufacturing method is used as for the magnesium alloy wheel. There are the following
three methods of manufacturing the aluminum alloy wheel.
(a) One Piece Rim
This is a method of the casting or the forge at the same time by one as for the rim and disc.
(b) Two Pieces Rim
This is the methods which separately manufacture the rim and disc
similar to the manufacture of the steel wheel and these components are welded afterwards.
(c) Three Pieces Rim
This is a method to manufacture each flange separately, and combining
later to the disc by welding.Each method is shown below.
(d) Forging Method (for One Piece Rim)
(d) Others
The test for welding between rim and disc and the nut seat
tightening etc. are provided in the vehicle test standard. Moreover,
nondestructive testing such as X- ray and color check, etc. is adapted to
the light alloy wheel to detect the defects in the casting process. Bead
Unseating Test, provided in the tire safety standards, for a mounted tire
and the rim is also applied.In addition tests are carried out in the field
with the assembly mounted on a vehicle under various road surfaces.
3.3.1 Use Limit of the Wheel
Though we think it is possible to permanently use a wheel until it rusts
away there is a limit to a wheels useful life. If a rim is used in severe operations such as
racing or rallying hidden damage is caused. This may result in an accident or sudden rim
failure whilst damage is caused. This may result in an accident or sudden rim failure whilst
the vehicle is in service. The life of a rim is varied according to using conditions. A rim
normally lasts longer than a tire so at time of a tire change a rim should be checked for
damage or sign of failure. If any are found the rim should be scrapped. In the case of steel
wheel, cracks and corrosions by rust at the joint parts of rim and disc, nut seats, between
decoration holes of the rim or the flange is bent, you should scrap the rim.
2.3.2Maintaining rims
Very necessary but often overlooked, it is vitally important to inspect
your motorcycle rims and clean them on a regular basis to help prevent spoke failure or
corrosion weak points. You can definitely suffer flat tires if a few spokes fail on your
motorcycle rims. This can happen under ordinary everyday conditions. The broken spoke
pushes into the wheel and punctures the tube. So always keep your wheels clean and check
them for signs of corrosion or other damage. It may only take one bad spoke to ruin your ride.
The aluminum motorcycle rims are usually coated. Some chemicals used for bike
maintenance of other systems (like brake fluid) can damage that coating. Once the bare
aluminum on the motorcycle rim is exposed to air it can begin to corrode. Wheels can come
under a lot of stress and even small areas of corrosion can become a point of failure.
Rim locks are used on wheels to prevent your tire from
slipping around your motorcycle rims. This can occur if you are running your tires
at very low pressures. They are quite common when bikers take to riding off
road. If your tire turns on the rim it can pull the valve stem through the wheel or
tear it off completely leaving you with a flat. They are fairly simple to install but
it requires removal of the tires and tubes and this can be more work than the rim
lock installation. The rear is the more critical of the motorcycle rims to lock as it
is subjected to the forces of driving the bike forward. Install them opposite the
valve stem to minimize the affect they will have on wheel balance
Examine the sidewall of the tire where it meets the rim to see if there is any indication
that the tire is not fully seated. This might show up as a slight variation in the measurement
between a mould line on the tire and the rims. This is best done on a centre stand if you
have one.
Have the installer correct any problem you find. Sometimes stock rims can be difficult
to seat properly (or unseat for that matter).
Sometimes what the tire installer will do to correct the problem is overinflate the tire
to force the tire to seat. TAKE CARE! I am not suggesting you try this yourself, it can be
very dangerous.
Also make sure the tire is installed correctly, arrow pointing in the direction of travel.
CHAPTER 3
LITERATURE
SURVEY
A wheel rim is a highly stressed component in an automobile
that is subjected to bending and torsional loads. Because of the long life and
high stresses, as well as the need for weight reduction, material and
manufacturing process selection is important in rim design. There are
competitions among materials and manufacturing processes, due to cost
performance, and weight. This is a direct result of industry demand for
components that are lighter, to increase efficiency, and cheaper to produce,
while at the same time maintaining fatigue strength and other functional
requirements.
A paper published in the year 2009,which is about the fatigue
analysis of aluminium wheel rim by Liangmo Wang* - Yufa Chen - Chenzhi Wang Qingzheng WangSchool of Mechanical Engineering, Nanjing University of Science
& Technology, China.
To improve the quality of aluminum wheels, a new method for evaluating
the fatigue life of aluminum wheels is proposed in that paper. The ABAQUS
software was used to build the static load finiteelement model of aluminum
wheels for rotary fatigue test. Using the method proposed in this paper, the
wheellife cycle was improved to over 1.010 5 and satisfied the design
requirement. The results indicated that theproposed method of integrating finite
element analysis and nominal stress method was a good and efficientmethod to
predict the fatigue life of aluminum wheels.
In this paper, for predicting the wheelfatigue life, the nominal
stress method wasintegrated into the CAD / CAE technology tosimulate the
rotary fatigue test. In addition, anactual prototype of the test was done to verify
theanalysis.
In the rotary fatigue test, a wheel wasspun to bear a moment to
simulate the process of turning corner continued the wheels abilitybearing the
moment, a wheel was mounted
on a rotatingtable. A shaft was attached to the center of thewheel where a
constant normal force was appliedas shown in Fig.3.1.
CHAPTER 4
(Computer
Aided
Three-dimensional
Interactive
DassaultSystems
Stable release
Operating
Unix / Windows
system
Type
CAD software
License
Proprietary
Website
WWW.3ds.com
Name/Versio
Latest
Build Original
n
CATIA v4
CATIA v5
CATIA v6
Number
R25
R20
R2012
Release Latest
Date
1993
1998
29/05/2008
Release
Date
January 2007
February 2010
May 2011
4.4APPLICATIONS OF CATIA
CATIA can be applied to a wide variety of industries, from
aerospace and defense, automotive, and industrial equipment, to high tech,
shipbuilding, consumer goods, plant design, consumer packaged goods, life
sciences, architecture and construction, process power and petroleum, and
services. CATIA V4, CATIA V5, Pro/E, NX (formerly Unigraphics), and Solid Works
are the dominant systems.
.4.1 Aerospace
The Boeing Company used CATIA V3 to develop its777
airliner, and is currently using CATIA V5 for the787 series aircraft. They have
employed the full range of Dassault Systems' 3D PLM products CATIA, DELMIA,
and ENOVIALCA supplemented by Boeing developed applications.
The development of the Indian Light Combat Aircraft has been using CATIA
V5.
Chinese Xian JH-7 A is the first aircraft developed by CATIA V5, when the
The Brazilian aircraft company, EMBRAER, use Catia V4 and V5 to build all
airplanes.
Vought Aircraft Industries use CATIA V4 and V5 to produce its parts.
The British Helicopter company, Westland, use CATIA V4 and V5 to
produce all their aircraft. Westland is now part of an Italian company called
Finmeccanica the joined company calls themselves AgustaWestland
4.4.2 Automotive
Many automotive companies use CATIA to varying degrees,
including BMW, Porsche, Daimler AG, Chrysler, Honda, Audi, Jaguar Land
RoverVolkswagen, Bentley Motors Limited, Volvo, Fiat, Benteler AG, PSA Peugeot
Citron, Renault, Toyota, Ford, Scania, Hyundai, Skoda Auto, Tesla Motors, Valmet
Automotive, Proton, Tata motors and Mahindra & Mahindra Limited.
Goodyear uses it in making tires for automotive and
aerospace and also uses a customized CATIA for its design and development.
Many automotive companies use CATIA for car structures door beams, IP
supports, bumper beams, roof rails, side rails, body components because
CATIA is very good in surface creation and Computer representation of surfaces.
Bombardier Transportation, Canada is using CATIA software to design its entire
fleet of Train engines, Coaches.
4.4.3 Ship building
Dassault Systems has begun serving shipbuilders with CATIA
V5 release 8, which includes special features useful to shipbuilders. GD Electric
Boat used CATIA to design the latest fast attack submarine class for the United
States Navy, the Virginia class. Northrop Grumman Newport News also used
CATIA to design the GeraldR. Ford class of super carriers for the US Navy.
Claas, and also various industrial equipment product companies like Alstom
Power and ABB Group
4.4.5 Other
Architect Frank Gehry has used the software, through the CCubed Virtual Architecture company, now virtual Build Team, to design his awardwinning curvilinear buildings. His technology arm, Gehry Technologies, has been
developing software based on CATIA V5 named Digital Project. Digital Project has
been used to design buildings and has successfully completed a handful of
projects.
4.4.6 Wheel rim nomenclature
Fig.5.1
rim
nomenclature
5.5. 2D Model of the wheel rim
Wheel