Structural analysis of wheels through analytical and experimental methods

New product development process requires a comprehensive approach that includes considering durability of the product, manufacturing methods etc. Analytical and experimental methods offer a strong decision capability for the manufacturers. These methods' relationship is complementary. Finite element analysis is important to take decisions before tooling manufacturing. In this way, tooling designs could be manufactured according to possible problems in the product manufacturing. A correlation between analytical and experimental results keeps the manufacturer in the safe zone. In this study, a wheel was investigated with a new rim size which is 8.25x20. The rim part of the wheel was performed in finite element analyzes and the physical radial fatigue tests with different material qualities and material thicknesses while disc part of the wheel kept equivalent. Finite element analysis' results taken from the software were used for fatigue life calculations. Firstly, a rim had material quality of S275 and material thickness of 5 mm was evaluated. As a result of the first part, mesh independence with the variation of 1% and difference of 6.71% between physical test and analytical result were obtained. Fatigue life cycle less than required was found in the first case. After reaching mesh independence and correlation between physical tests and analytical results, a rim had material quality of S420 and material thickness of 6 mm was conducted in the physical test and finite element analysis. High cycle values from experiments and analytical results were considered durable enough to carry wheel load capacity that is 2270 kg. However, a weight reduction between first and second cases was desired. Therefore, additional rim option with 5.5 mm thickness was designed. Also, material quality of the rim was decreased to S275. A wheel reduction of 8.26% was reached with this case when compared with the second case. Also, maximum principal result decreased from 303.28 MPa to 255.51 MPa on the rim part when compared to first case and a design ensure required fatigue life cycle.