Optimization of Aluminum Alloy Wheel Design based on Improved Experimental-Numerical Stress Correlation

Automotive manufacturers continuously seek to improve vehicle performance by developing components that are safe, fuel efficient, and lightweight. Reducing the unsprung weight, particularly through wheel optimization, is a key focus area due to its direct impact on vehicle dynamics and efficiency. The wheel, a critical component of the suspension system, must withstand both static and dynamic loads while maintaining structural integrity. This study aims to analyze the stress distribution in an aluminum alloy wheel, identify discrepancies between experimental and numerical results, and develop a methodology to improve the correlation between experimental stress analysis (ESA) and finite element analysis (FEA). Ultimately, the goal is to use this improved correlation to optimize wheel design in terms of fatigue life and structural strength. ESA was conducted on a standard aluminum alloy wheel using a developed test bench to simulate loading condition as per the standards. The same setup was modeled using FEA to identify stress distribution and critical regions. Discrepancies between ESA and FEA were investigated through material characterization and refinement of the experimental test setup. A methodology was proposed to enhance the accuracy and consistency of the correlation between ESA and FEA results. Fatigue tests were subsequently conducted on the wheels to validate the analytical predictions. The proposed methodology effectively minimized the deviation between ESA and FEA results to within 3%–6%, ensuring higher reliability in stress prediction. The enhanced correlation enabled an optimized wheel design, achieving a 7.82% reduction in excess material while maintaining structural integrity, safety, and performance standards. Comparative analysis between the baseline and optimized wheel designs showed enhancements in fatigue life and structural strength. Overall, the proposed approach not only strengthens the correlation between experimental and numerical analyses but also enables the design of lighter and stronger alloy wheels that comply with automotive performance and safety requirements.