Validation of experimental impact tests on aluminum alloy car wheels using the finite element method

Aluminum alloy wheels for passenger cars are subjected to some performance tests in the production process. These tests are so important for the supplier and the customer because of the wheel is a safety part of a car. In the design process, the design is supported by simulations to ensure optimum design. Accurate results from these simulations allow to accelerate the design process and make it easier to detect the design error that may be noticed on the wheel after manufacture. In this study, fundamental procedures about aluminum alloy wheel is given and manufacturing process is mentioned. Moreover, the tests applied to the wheels are mentioned. It is mostly here is focused on physical impacts tests and their numerical validation by governing a proper constitutive material model. The data obtained from tensile tests are analyzed, strain rate effect is investigated in Johnson-Cook material model and its effects on simulation results are examined. As a result, it is concluded that the strain rate affects the numerical data which shows that it should be included in constitutive material model to obtain more realistic simulations.