Anti-Cracking Design For Inner-Rim Cracking Of Low-Pressure Casting Wheele Of Al-Alloys Based On Dymatic Test Failure Mode

It is known that the first car was built in 1886. Originally, the car was invented as a tool replacing the carriage, however, in nowadays, it has become an essential in people’s daily lives and is granted with feature of times. Besides, under developments and perfection in the past 120 years, the role of car is now a comfortable and enjoyable daily consumer product rather than a simple tool for riding. Then gradually, comfort and safety turns to be the trend of car development. Accordingly, the aluminum wheel, as the safety bearing components of whole chassis, plays a more important part in safe driving of automotive. Styling of wheels varies but the safety validation methods such as fatigue tests, biaxial test, road test etc stay unchanged. In this essay, the author introduced the design study to prevent inner rim crack caused by Dynamic Test which is not same as those tests mentioned above but has been drawing more and more attention from automakers.In this essay, the author brings up a new rim design idea which exceeded the customer design rules based on experiences of study on the inner rim crack wheels he designed and also the process of wheel design perfection which includes analyzing the wheel application environment and implementing analysis and optimization of low pressure cast molds, production process as well as design theories under Magma Software. The new idea was finally accepted and implemented, which help wheel pass the dynamic tests and optimize the design standards from customer.Under Magma software, the product’s mold temperature fields and mold filling simulation will be analyzed to optimize the air exhaust system, cooling system, liquid aluminum injection channel design and other factors related. Though solving the problems of molds, the designed mold can be optimized at largest extent in physical condition and almost same to actual mold condition. Accordingly, inner rim of wheel performs excellent in mechanical property and metallographic analysis, which enables the wheel pass customer’s strict tests in field.Based on the analysis of software and also actual test results, the inner rim design styling is approved by customer and also included in customer’s design spec, Design Rules, as amended standard which has been popularized in the design field.The requirement of heavy load under severe usage conditions brings an unprecedented challenge to wheel design, which not only requests the experienced designer be close to actual production when dealing the problems but also requests designer’s effective judgment on results from software. Though digesting the analysis, the designer should be able to make good use of simulation results and absorb key factors which enables the high output of molds, guides mold modification and setting for boundary conditions, properly matches difference between design and production, makes largest use of the mold efficiency, shortens the development period and makes good profit for company.