1.

Abstract:(Component Selection)
The purpose of this report is to study the manufacturing process of a vehicle
component. I am selecting wheel hub for my project because it is a most important component
of vehicle. Wheel hub assemblies are a combination of parts that connect to the trailer tire.
The purpose of the wheel hub is to serve as the glue between the tire and the axle. Tires are
attached with studs to the hub assembly. The hub assembly then fits on the axle, which
connects the tire component to the rest of the car.
2.Manufacturing processes:
In order to manufacture wheel hubs following processes takes place
in series.

1. Creo Modelling.

2. Loading Analysis in Ansys.

3.Material selection.

4. Pattern making using CNC machining.

5. Casting using sand molds.

6. Machining using CNC after casting.

7. Quality assurance.

2.1.Creo Modeling:

First of all wheel hubs are designed using creo and solid works software.
2.2.Ansys Load Analysis:

After making a solidworks or creo model this model is then imported

to ansys and then loadings are applied to check its feasibility.

2.3.Material Selection:

Basically two types of materials are used in order to make wheel hubs.

1. Cast Iron

2. Grey Iron

2.3.1.Cast Iron:

Cast iron properties are mentioned below:

A few common mechanical properties for cast iron include:

 Hardness – material’s resistance to abrasion and indentation

 Toughness – material’s ability to absorb energy
 Ductility – material’s ability to deform without fracture
 Elasticity – material’s ability to return to its original dimensions after it has been
deformed
 Malleability – material’s ability to deform under compression without rupturing
 Tensile strength – the greatest longitudinal stress a material can bear without tearing
apart
 Fatigue strength – the highest stress that a material can withstand for a given number of
cycles without breaking
Commonly used cast iron grades:

Ductile cast iron casting is manufactured under

European standard EN 1563:1997 Some grades are mentioned below:

2.3.2. Grey iron:

Grey iron casting is manufactured under European standard EN

1561:1997 Some grades are mentioned below:

2.3.3. Selected Material: (EU-GJS-500-7)

Ductile cast iron I am selected to make our wheel hub project.

Ductile iron itself can be broken down into different grades, each with their own property
specifications and most suitable applications. It is easy to machine, has good fatigue and
yield strength, while being wear resistant. Its most well-known feature, however, is
ductility. Ductile iron can be used to make steering knuckles, plow shares, wheel
hub,crankshafts, heavy duty gears, automotive and truck suspension components,
hydraulic components, and automobile door hinges.
 2.4.Pattern making using CNC:

For casting purpose pattern is made using CNC machine. We

can make the whole wheel hub using CNC but the time and cost of the process will
increase so the process will not as much feasible as casting. Although CNC machining is
highly accurate than casting but casting consume less time and that accuracy is enough
for us after a little bit machining.

2.5. Casting using sand molds:

High pressure sand casting is performed to make wheel hubs.

Following are the processes for casting quality assurance.

1. High pressure molding line.

2. Eirich sand system.
3. Metal treatment using sandwich process.
4. Metallurgical quality control.
5. Ultrasonic flaw detection.
6. Impact testing at -30 degree.
7. Chemical and mechanical testing.

2.6. Machining using CNC after casting:

After performing casting at high pressure we

should have to perform some machining operations to make is usefull like drilling facing etc.
2.7. Quality Assurance:

For wheel hub quality assurance purpose we should have following labs
and equipments.

1. Metallurgical testing equipment.

2. Dimensional testing equipment

3. Sand testing lab.

2.7.1. Metallurgical testing equipment.

1.Tensile testing equipment.

2.Hardness test.

3.Ultrasonic flaw test.

4.Ultrasonic nodular test.

5.Impact testing by cryogenic chamber(-30c)

2.7.2. Dimensional testing equipment:

1.Co-ordinate measuring machine.

2.Profile projector.

3.Brust test machine.

4.Surface roughness tester.

2.7.3. Sand testing lab:

Sand testing is done daily to check the quantity of different components

in it to make this sand in sand testing labs.