Design, Strength Analysis, and Laboratory Verification Testing Evaluation of an Aluminum Wheel Rim

Abstract

This study examines the design and validation process of aluminum alloy wheels, which requires the integrated consideration of customer requirements, manufacturability constraints, international standards, and structural performance criteria. The main objective of the study is to present the key stages of wheel development, including concept selection, determination of technical specifications, CAD modeling, finite element analysis (FEA), tooling and machining preparation, and laboratory validation testing. Particular emphasis is placed on the fatigue cornering, radial fatigue, and impact tests conducted in accordance with ECE R124 requirements. In addition, the study investigates the potential discrepancies between simulation predictions and experimental test results, focusing on factors such as material discontinuities, surface quality, stress concentration effects, and differences between nominal and mean stress conditions. The findings demonstrate that reliable aluminum wheel design cannot rely solely on numerical simulations; laboratory testing and production-based material characterization are also essential for ensuring structural integrity, safety, and compliance with industry standards.