Multi-objective structural optimization of vehicle wheels: a method for preliminary design

Abstract The paper proposes an optimization procedure to be adopted by wheels design engineers for the identification of preliminary solutions to design lightweight and safe wheels. In particular, decisions related to the sizing of the wheel rim, to the number and type of spokes and to the spokes structural layout are addressed. The process relies on the combination of a simplified finite element model of the tire/wheel assembly and artificial neural networks used for global approximation, within a multi-objective optimization framework. Mass and compliance of the wheel are minimized at the same time, with constraints on structural safety and manufacturing. The method is applied to the preliminary design of the wheel of a lightweight electric vehicle specifically designed for energy efficiency competitions and allows to derive simple and general design guidelines for developing efficient products.