2
Carbon Fiber Wheel Rim
Client
Bachelor Thesis
Date
January 2025
Practecies
Structural Analysis, Material Engineering
Tools
Autodesk Inventor, Solid Edge, Ansys Mechanical
This thesis investigates the material substitution of a rim star under consideration of carbon fiber reinforced plastics (CFRP) as an alternative to commonly used aluminum alloys. The aim is to design a lighter and more resilient component. In the context of this work, only the choice of materials is undertaken; a topology optimization is not performed. In the preliminary review, the material engineering knowledge of CFRP, the basics of an analysis model using the finite ele-ment method (FEM), the requirements for a material for a rim star and the framework conditions of a simulated test are covered.
Context
Current research and development in carbon fiber reinforced plastics (CFRP) for automotive applications is strongly focused on weight reduction and performance optimization. CFRP wheels offer significant advantages over currently used metal wheels due to their lower unsprung mass, which positively affects a vehicle's driving dynamics and efficiency through reduced drivetrain energy consumption.
Task
The objective of this study is to conduct a strength analysis of the wheel rim star made from carbon fiber reinforced plastic (CFRP), with the aim of replacing the aluminum alloy 6061 T6 currently used in established wheel designs. This involves selecting a suitable CFRP material system and carrying out an FEM-based feasibility study to evaluate whether the proposed composite design can meet the structural and performance requirements currently fulfilled by the aluminum alloy.
Scope
The results of the simulation are selected safety factors, deformations, reference and principal stresses and specific failure criteria for fiber composites. Depending on the simulation case, associations between the mechanical properties of the materials, the fiber orientation and the component thickness in relation to the component strength are investigated.
Outcomes
- 59,8 % weight
The analysis shows a theoretical weight reduction of 59,8 % , compared the the Al 6061 competitor, for the wheel rim star.
Fiber Angle
Deflections and stresses correlate to fiber orientations. Especially the top and bottom layers can be adapted to optimise for a specific spoke design.
Feasability
FEM simulations with various matrix-fiber combinations demonstrate that the structural durability of the CFRP component is on par with conventional aluminum wheels.
