Abstract:
The present research was devoted to designing a plastic rim for industrial and
commercial light vehicles using modeling and simulation tools.
The main objective of the design project was to design a rim structure that would be
capable of sustaining the required load and performing under provided
conditions. In order to select a suitable thermoplastic composite a series of plastics
was experimented. The selection of material was based on several factors, including
mechanical strength under dynamic load, resistance to prolonged action of elevated
temperatures and ability to be molded with conventional techniques. The materials
which were considered for the design included Polyamide 6, Polyamide 6 with 50%
long glass fibers, Polyamide 6 with 50% short glass fibers and Polyamide 6 with 30%
short glass fibers, out of which Polyamide 6 with 30% short glass fibers was selected
due to it being less brittle, that aided the material to withstand service and accidental
impact. Another criterion that supported selected material was associated with its
ability to be injection molded with conventional type injection molding techniques.
Four models were developed based on general plastic product design standards. Each
model was simulated in order to identify areas of potential failure. After that model
was optimized by changing its structural arrangements so as the stresses in the
potential failure areas were reduced. Next step in modification and optimization ofthe
model was done for product mold-ability.
The model which comprised a solid body of rim portion with a center bore
configured to receive axle hub, an inner band, a circumferentially extended outer band
that margined the rim portion, a nave ring that extended outwardly and radially ofsaid
center bore wherein a plurality of holes were circularly positioned that were
configured to receive bolts, a plurality of ribs extending outwardly and radially at
right angles from the nave ring up to the outer band were positioned both sides ofthe
rim configured to improve flexural rigidity of the structure was accepted for
fabrication by means ofreinforcement of hub hole area with metal plate.
A manufacturing method of plastic rim was selected based on the material
processbility, manufacturing cost and efficiency for serial manufacturing and
commercialization. Prototype Injection mold was manufactured using cheap and easy
to machined steel P-20. Produced standard mold was modified to improve ventilation
and to facilitate flow of the plastic melt through the flow path of the injection mold
from machine nozzle to cavity
The successful prototypes and destructive tests carried out affirmed suitability of the
Solidwork Design package and Solidwork Simulation Package for designing,
manufacturing and prediction of load bearing capability of the plastic rim. The
application of Solidwork Simulation Package during designing stage lead to reduced
implementation cost and reduced reproduction numbers of prototypes to evaluate
product suitability, thereby making implementation ofthe final product efficient.
The main advantages of using plastic composite material for automotive rims
included energy efficiency and easy maintenance due to lower weight