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<p>The manufacturing industry has undergone a remarkable shift with the advent of Metal Additive manufacturing (AM) technology, which offers unmatched design and optimization flexibility. The Wheel hub, which is a vital component in an automobile, transmits power from the driveshaft to the wheel for which the component must be of great strength and durability. The present work aims to develop a high-performance wheel hub for automotive applications utilizing the Aluminum-based alloy AlSi10Mg. Using AM for automotive parts enhances its importance in smart manufacturing which offers freedom for complex designing resulting in reduced weight. The study uses physical testing and a numerical approach to assess the wheel hub performance and force calculations to attain a real-life applicable component. It was found that AlSi10Mg is one of the most suitable materials that can be used to fabricate a wheel hub. The present work is done by designing, followed by topology optimization based on force calculations in Ansys. The experimental testing leads to results that are taken as input for calculations. Future research will be concentrated on identifying better ways to optimize the existing wheel hub design and, if relevant, adopt a better production process. After analysis, It was found out that the maximum von-Mises stress is 110–120&#xa0;MPa and the deformation ranges from 0.15 to 0.25&#xa0;mm with FOS ranging in 2.5–2.8 which falls under the real-life application which resulted in a weight reduction of 32.62% by using topology optimization, increasing the vehicle’s performance and efficiency.</p>

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Analysis of equivalent stress, topology optimization and additive manufacturing of a wheel hub using AlSi10Mg

  • 期刊论文

  • 发表日期：

    2025年6月13日

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  • Shyam K. Ladhad,
  • Yetin Sai,
  • Rajesh Ramesh,
  • Nishan A. Bandekar,
  • Mantesh B. Khot

摘要

The manufacturing industry has undergone a remarkable shift with the advent of Metal Additive manufacturing (AM) technology, which offers unmatched design and optimization flexibility. The Wheel hub, which is a vital component in an automobile, transmits power from the driveshaft to the wheel for which the component must be of great strength and durability. The present work aims to develop a high-performance wheel hub for automotive applications utilizing the Aluminum-based alloy AlSi10Mg. Using AM for automotive parts enhances its importance in smart manufacturing which offers freedom for complex designing resulting in reduced weight. The study uses physical testing and a numerical approach to assess the wheel hub performance and force calculations to attain a real-life applicable component. It was found that AlSi10Mg is one of the most suitable materials that can be used to fabricate a wheel hub. The present work is done by designing, followed by topology optimization based on force calculations in Ansys. The experimental testing leads to results that are taken as input for calculations. Future research will be concentrated on identifying better ways to optimize the existing wheel hub design and, if relevant, adopt a better production process. After analysis, It was found out that the maximum von-Mises stress is 110–120 MPa and the deformation ranges from 0.15 to 0.25 mm with FOS ranging in 2.5–2.8 which falls under the real-life application which resulted in a weight reduction of 32.62% by using topology optimization, increasing the vehicle’s performance and efficiency.