Optimizing Car Wheel Rim Mass and Design: A Composite Material Approach with Finite Element Analysis

Authors

  • Dheeraj Malewadkar Mechanical Engineering Department, G H Raisoni College of Engineering and Management, Pune, India Author
  • HIMADRI MAJUMDER Mechanical Engineering Department, G H Raisoni College of Engineering and Management, Pune, India Author

DOI:

https://doi.org/10.64229/qgykhh08

Keywords:

Finite Element Analysis (FEA), Car wheel rim, Lightweight wheel rim, Structural optimization, Hybrid composite materials, Rim construction

Abstract

Weight reduction in vehicles remains a central priority in the automotive industry, as it directly affects fuel economy and emissions. Wheel rims, being among the unsprung components, offer considerable scope for lightweighting through material and design optimization. This research evaluates the replacement of conventional aluminium alloy rims with advanced composite materials, aiming to minimize mass without compromising structural strength and durability. A comprehensive Finite Element Analysis (FEA) framework is employed to compare the baseline aluminium alloy rim with an optimized composite design. The investigation encompasses stress distribution, deformation characteristics, and modal response under representative static and dynamic loading conditions. The results reveal that composite rims can achieve notable reductions in weight while sustaining the required structural performance. While the optimized carbon fiber composite rim demonstrates significant mass reduction compared to the baseline aluminium alloy, it exhibits a modest increase in maximum deformation under peak loading conditions. Preliminary cost analysis indicates higher material and manufacturing expenses, highlighting a trade-off between performance gains and economic considerations. These findings demonstrate the potential of composite materials to enhance vehicle efficiency and support the broader goals of sustainable and energy-efficient automotive engineering.

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Published

2025-11-24

Issue

Vol. 1 No. 1 (2025)

Section

Articles

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Copyright (c) 2025 Dheeraj Malewadkar, HIMADRI MAJUMDER (Author)

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