Finite element simulation and experimental validation of the cracking phenomenon in aluminium alloy wheels during the impact test

The impact test is a mandatory mechanical test used to ensure the structural integrity of alloy wheels produced. In the impact test, a specified mass is dropped from a specified height onto the wheel-tyre assembly. In the wheel manufacturing industry, finite element analysis (FEA) is often used to reduce time and cost associated with the wheel design process. This study aims to find suitable methods for modelling the wheel impact test by FEA. In this research, two modelling methods (with and without the tyre) were used to simulate the impact test of a passenger-car wheel model. The wheel impact test was performed in order to validate the real test results with the FEA results. The results in this work suggest that both modelling methods are capable of predicting the cracking phenomenon in the wheel.