International Journal of Automobile Engineering

Research & Development (IJAuERD)

ISSN 2277-4785
Vol. 3, Issue 1, Mar 2013, 97-106
© TJPRC Pvt. Ltd.

FAILURE ANALYSIS OF WHEEL RIM

TRAPTI SHARMA1, MUGDHA SHRIVASTAVA2 & PRATESH JAYASWAL3

1,2
Assistant Professor, ME Department, SRCEM Gwalior, India
3
Professor, ME Department, MITS Gwalior, India

ABSTRACT

In present scenario all manufacturing companies and service providing companies approaching to work at optimal
level and minimum defects as much as possible, for that their employees making effort day and night. Here we analyze
their wheels and scrap material during manufacturing process. I concentrated on failure analysis of wheel during
manufacturing process and conduct some tests on wheel such as weld shear strength test, nut rigidity test, air leak test,
wheel static and dynamic test etc. but in our project work we focus on corner fatigue test and radial fatigue test. Blank
size reduction process is implemented for eliminating failure from wheel in industries. This process helps in elimination of
failure in manufacturing process and also to detect the problem. After analysis the failure, we expose the problem area and
give appropriate solution and suggestion which results in the elimination of problem in wheel and also increase profit of
industry by giving more scrap material as well as reduce the weight of the wheel.

KEYWORDS: Failure Analysis, Blank Size Reduction Process

INTRODUCTION

STEEL STRIPS WHEELS LTD was established in 1985 and its commercial production started in 1991. The plant
is situated in village Lehli. Tehsil Derabassi, Distt. Mohali on the Chandigarh - Ambala highway at a distance of about 30
km. from Chandigarh. It has an installed capacity of 7.5 lakh Plus wheels per month. The company has a technical
collaboration with Ring Tech Company of Japan. The Steel Strips Group has its head office in Chandigarh. The SSWL
plant is ISO-9000, QS-9000, TS-16949 9000 & ISO 14001 certified, manufacturing single piece steel wheel rim in a
diameter range of 12" - 28" for automotive vehicles. There are very well experienced staff members consisting of
engineers, administrative staff, executives and clerical staff. Company turnover is 600 crores. Total area is 1, 60,000 sqmt,
covered area is 30,000 sqmt and uncovered area is 1, 30,000 sqmt. Total numbers of employers is 1500.

Research & Development Process of Wheel Rims

98 Trapti Sharma, Mugdha Shrivastava & Pratesh Jayaswal

Manufacturing Process

Tests Applied on Wheel

For the testing of wheel we conduct some tests they are as follows [1]:-

• Flange bend test

• 3-D coordinate measuring machine for dimensional checking

• Weld shear strength test

• Nut rigidity test

• Wheel static and dynamic balancing machine

• Automatic run out and low point marking machine (on line)
Failure Analysis of Wheel RIM 99

• Air leak test (on line testing)

• UTM for raw material physical analysis

• Salt spray test chamber

• radial fatigue test

• Corner fatigue test

METHODOLOGY

In the failure analysis of wheel rim we conduct above tests but in our project work we concentrate only on corner
fatigue test and radial fatigue test.

Radial Fatigue Test

RFT known by Radial fatigue load [2], In this test radial load is applied on the rim assembly means this test is
perform after tyre mounted on the rim then the wheel has to be fixed on the shaft of RFT machine through M12 bolt on
particular torque then shaft starts rotates and it also continue rotating till crack not comes on the crown area then we noted
down the no. of cycles at which crack comes.

If it is as per standard then rim is OK and if it came before standard cycle then it is NG part and R & D have to
start working on its improved design. It is also sample basis test.

Figure 1: Radial Fatigue Test Rig-I

Figure 2: Radial Fatigue Test Rig-II

100 Trapti Sharma, Mugdha Shrivastava & Pratesh Jayaswal

RADIAL FATIGUE TEST REPORT

DRAWING
CUSTOMER MSIL CA-4Jx13-233
NO.
YR9-13
MODEL PART NO. 43210-67L00
INCH
WHEEL SIZE 4Jx13 REFERENCE STD. ISO 3006
MATERIALS
RIM 2.4 mm /SAPH370 or Eq.
DISC 2.9 mm /SAPH440 or Eq.
TEST SPECIFICATION
BENDING MOMENT 7.72 KN-m
NUT TIGHTENING TORQUE 120 N-m
NO. OF CYCLES ≥ 5,00,000
TEST RESULTS
WHEEL NO. OF
REMARKS
NO. CYCLES
6,00,000 (Test -No Crack observed during the test.
1
Discontinued) -No abnormal bolt looseness and deformation was observed during the test.
5,50,000 (Test -No Crack observed during the test.
2
Discontinued) -No abnormal bolt looseness and deformation was observed during the test.

CONCLUSIONS

The wheels have cleared the min. load cycle specified without any failure and hence passed the RFT.

• The Radial fatigue test is successfully held there is no cracks observed and no abnormal bolt looseness and no
deformation was observed during the test.

• The wheels have cleared the min. load cycle specified without any failure and hence passed the Radial Fatigue
Test.

Corner Fatigue Test

CFT is a corner fatigue test used for the testing of wheel rim performance at time of turning. CFT [3] is used only
for steering wheel of vehicle. In this test bending moment is applied at 1.27 KN-m on the rim in dynamic condition. Rim
has to be bolted on particular torque generally 12 Kg-m and testing start. In CFT method we run wheel up to 1,00,000 rpm.
It takes near about 8 hrs. for complete testing.

Figure 3: Corner Fatigue Test Rig-I

Failure Analysis of Wheel RIM 101

Figure 4: Corner Fatigue Testrig – II

CORNER FATIGUE TEST REPORT-1

CUSTOMER MSIL DRAWING NO. CA-4Jx13-233
MODEL YR9-13 INCH PART NO. 43210-67L00
WHEEL SIZE 4Jx13 REFERENCE STD. ISO 3006
MATERIALS
RIM 2.4 mm /SAPH370 or Eq.
DISC 2.9 mm /SAPH440 or Eq.
TEST SPECIFICATION
BENDING MOMENT 1.27 KN-m
NUT TIGHTENING TORQUE 120 N-m
NO. OF CYCLES ≥ 1,00,000
TEST RESULTS
WHEEL NO. OF
REMARKS
NO. CYCLES
-Crack observed at mounting face.
1 1,60,000
-No abnormal bolt looseness and deformation was observed during the test.
-Crack observed at mounting face.
2 1,50,000
-No abnormal bolt looseness and deformation was observed during the test.
-Crack observed at mounting face.
3 1,35,000
-No abnormal bolt looseness and deformation was observed during the test.
102 Trapti Sharma, Mugdha Shrivastava & Pratesh Jayaswal

CONCLUSIONS

The wheels have not cleared the min. load cycle specified without any failure and hence failed the CFT.

1. Crack observed at mounting face.

2. No abnormal bolt looseness and deformation was observed during the test.

3. The wheels have not cleared the min. load cycle specified without any failure and hence failed the CFT.

Photographs of Failure Occur During CFT

Figure 5: Failed Wheel 1

Figure 6: Failed Wheel 2

Figure 7: Failed Wheel 3

Blank Size Reduction Method

Blank size reduction method is to overcome the failure of wheel. In manufacturing of disc this process is known
Failure Analysis of Wheel RIM 103

as blanking process and in assembly of wheel this process is known as blank size reduction process. The blank size
reduction process is for elimination of unused area from disc [4]. In a disc there is some non-functional part that part only
increases the weight of the disc we eliminate this non-functional part by using the blanking reduction process through
value added or value engineering. For the minimization of stress concentration we reduce the weight of wheel from the
disc due to which the sudden change in area is prohibited, if we reduce the weight from any other place we have to
redesign the wheel and this will consume more time. In our project we use this process two times firstly when we
manufactured disc & second time when we assemble disc and rim. The remove material is not the wasted material it goes
to the scrap from which company earns profit.

Our Work on Wheel through Blank Size Reduction Process

Figure 8: Show Elimination of Unused Area

104 Trapti Sharma, Mugdha Shrivastava & Pratesh Jayaswal

We eliminated the unused material by which we minimize the stress concentration on the crown area of wheel.
We tried to eliminate the cause of failure of wheel and also reduce the cost of wheel. We increase the scrap material from
which company earns profit of Rs. 5.23 per wheel by selling of scrap.

Figure 9: Shows Stress Concentration on Wheel

In the fig 9, we show wheel before application of blank size reduction method and after application of blank size
reduction method. The red colour shows the highly stress concentrated area where chances of failure is more [5]. The blue
colour shows the safe area it means this area is free from high stress. The first fig shows high stress up to 307 MPa but
after applying blank size reduction method the stress reduces up to 263 Mpa in second fig. The weight is also reduce from
the disc area with the help of blank size reduction method we reduces the weight of 0.29 kg from the wheel. The Corner
fatigue test is successfully held the results of this test are up to the mark that means there are no cracks observed at
mounting face and no abnormal bolt looseness and deformation was observed during the test. The wheels have cleared the
min. load cycle specified without any failure and hence passed the Corner Fatigue Test

CORNER FATIGUE TEST REPORT-2

CUSTOMER MSIL DRAWING NO. CA-4Jx13-233
MODEL YR9-13 INCH PART NO. 43210-67L00
WHEEL SIZE 4Jx13 REFERENCE STD. ISO 3006
MATERIALS
RIM 2.4 mm /SAPH370 or Eq.
DISC 2.9 mm /SAPH440 or Eq.
TEST SPECIFICATION
BENDING MOMENT 1.27 KN-m
NUT TIGHTENING TORQUE 120 N-m

NO. OF CYCLES ≥ 1,00,000

TEST RESULTS
NO. OF
WHEEL NO. REMARKS
CYCLES
-No Crack observed at mounting face.
1 1,60,000
-No abnormal bolt looseness and deformation was observed during the test.
-No Crack observed at mounting face.
2 2,50,000
-No abnormal bolt looseness and deformation was observed during the test.
-No Crack observed at mounting face.
3 3,60,000
-No abnormal bolt looseness and deformation was observed during the test.
Failure Analysis of Wheel RIM 105

CONCLUSIONS

The wheels have cleared the min. load cycle specified without any failure and hence passed the CFT.

RESULTS

YR9 Project Raw Material & Tooling Details 04-12-2010

Raw Material Costing Lxi-13 x 4J Wheel Rim
BLANK SIZE WEIGHT COST
GRO FINI SCR RM RM SCRAP SCRAP
Grade L W THK
SS SH AP RATE COST RATE RECEV.
mm mm mm Kg Kg Kg INR/Kg INR INR/Kg INR
YR-9
MKTG.
Actual Part No. 43210-67L00
WTS.
RIM KICF(SAPH-370) 1000 165 2.40 3.26 3.19 0.07 47.01 153.35 18.00 1.30
O DISC FB-590/Equ 371 370 2.90 3.28 2.50 0.78 49.51 162.35 18.00 14.02
WHEEL 6.54 5.69 0.85 315.69 15.32
RIM KICF(SAPH-370) 1000 165 2.40 3.26 3.03 0.23 47.01 153.34 18.00 4.19
N DISC FB-590/Equ 371 370 2.90 3.28 2.37 0.91 49.51 162.35 18.00 16.36
WHEEL 6.54 5.40 1.14 315.69 20.55
5.23

The obtained scrap is more as compared to earlier process so we earn more profit with perfect wheel. With the
help of CFT & RFT tests and blank size reduction process we eliminated some unused area from the wheel which helps in
the prevention of wheel from failure.

CONCLUSIONS

• With the help of CFT & RFT tests and blank size reduction process we eliminated some unused area from the
wheel which helps in the prevention of wheel from failure.

• The obtained scrap is more as compared to earlier process so we earn more profit with perfect wheel.

• The development time is saved by only disturbing the last 5 week out of 30 weeks.

FUTURE SCOPE

In future we can work on elimination of failure of wheel through these processes:

• Disc thickness reduction.

• Rim thickness reduction.

• Usage of high tensile material.

• Disc & rim profile change.

• Styled wheels.

REFERENCES

1. L. Hagler (July 21, 2008) “ILC target wheel rim fragment/guard plate impact analysis” Lawrence Livermore
National Laboratory.
106 Trapti Sharma, Mugdha Shrivastava & Pratesh Jayaswal

2. P. Laczko and P.J. Mutton (2006) “Metallurgical and NDT aspects in the management of overheated railway
wheels” materials forum.

3. Martin Ertz (2002) “A comparison of analytical and numerical methods for the calculation of temperatures in
wheel/rail contact” Berlin, Germany.

4. G. Kosec (2009) “Cracking of an aircraft wheel rim made from AL-alloy 2014-T6”.

5. Sam Kodsi (2006) “Failure Analysis: Passenger Vehicle Wheel Separations”.