FINITE ELEMENT-BASED STATIC ANALYSIS OF ALLOY WHEEL RIMS WITH CARBON/EPOXY COMPOSITE, ALUMINUM ALLOY 6061, AND STAINLESS STEEL

Abstract

The alloy wheel rim is a critical component of an automobile that directly influences vehicle safety, load-carrying capacity, handling performance, and fuel efficiency. The selection of an appropriate material for wheel rim construction plays a significant role in achieving enhanced structural strength while minimizing weight. This study presents a finite element-based static analysis of alloy wheel rims manufactured using Carbon/Epoxy Composite, Aluminum Alloy 6061 (Al6061), and Stainless Steel. A threedimensional wheel rim model was developed using computer-aided design (CAD) software and subsequently imported into a finite element analysis environment for structural evaluation. Identical loading and boundary conditions representing typical vehicle operating scenarios were applied to all material models to facilitate a fair comparison. The analysis focused on key performance parameters including total deformation, equivalent (von Mises) stress, strain distribution, and weight characteristics. Finite element simulations were performed to investigate the structural response of each material under static loading conditions. The obtained results indicate significant variations in deformation behavior and stress distribution among the selected materials. Carbon/Epoxy Composite demonstrated superior weight reduction with acceptable structural performance, while Aluminum Alloy 6061 provided a balanced combination of strength, stiffness, and lightweight characteristics. Stainless Steel exhibited the lowest deformation due to its high stiffness but resulted in increased wheel weight, which may adversely affect vehicle efficiency. Comparative evaluation of the simulation outcomes reveals that material selection substantially influences wheel rim performance and durability. The study highlights the advantages of advanced composite materials for automotive wheel applications and demonstrates the effectiveness of finite element analysis as a reliable tool for material assessment and design optimization. The findings contribute to the development of lightweight, durable, and highperformance wheel rim designs for modern automotive engineering applications.