Intruction of Wheels Test
The wheel being critical component in the vehicle has to meet strict requirements of driving safety. The wheel design must meet both the styling appearance and engineering functions. The wheel also must be durable enough to withstand rough loads and harsh environments. Wheel weight and manufacturing cost should be minimized without contradicting the safety requirements. The wheel design and development use three main wheel tests (rotating bending test, radial fatigue test, and impact test) to test a prototype wheel for various fatigue and durability considerations
The rotating bending test simulates cornering induced loads by applying a constant rotating bending moment to the wheel. In the radial fatigue test, the wheel and tire assembly is loaded radially against a constantly rotating drum. The impact test is established to evaluate the impact characteristics of passenger car wheels. The time to test and inspect wheel during production is very consuming. For economic reasons, it is important to reduce the time spending in trial and error during the development and testing phase of wheel. Computer simulation of wheel tests can significantly reduce the time and cost required to finalize a wheel design. The simulation of rotating bending test and radial fatigue test have shown good agreement with experimental results[3-5]. Riesner et. al. employed three step analysis to simulate the impact test: static, dynamic, and fracture mechanics. A static finite element simulation is carried out to obtain an effective spring constant of wheel. Then a simple model consisting of lumped masses, springs, and dampers is performed to simulation the dynamic response. In the third step, the peak force acquired the dynamic response is applied to the finite element model to calculate the stress and strain energy density. The total plastic work is utilized as a damage criterion to predict a wheel failure. In this study, the nonlinear dynamic finite element analysis is performed to simulate a forged aluminium wheel during SAE impact test. The strain, stress, and strain energy density distribution are obtained from finite element results. The structural damage parameter of the wheel is estimated by the strain energy density, and the fracture criterion is based on the total plastic work of the wheel material.The nodes at the contacted surface between the wheel and support are constrained to move together. The striker is modeled as a rigid body. The displacement of striker is constrained to move in vertical direction.