FE Analysis of Automobile Hub

FEM Self Study

Abhinav Sapare
1RV16ME003
Introduction-FEA
• Finite Element Analysis- A powerful, modern mathematical technique
that can be used to compute, model and calculate precisely various
physical phenomena and perform structural analysis successfully on
components/machines, where the classical approach generally is
unsuitable.
• The evolution and growth in computers/computing power has led to
exponential increase in the usability of FEA as a software tool.
Hub of Automobile
• The wheel hub of an automobile, also known as the hub assembly, is the
mounting assembly for the wheels of a vehicle. It houses the wheel bearing
as well as supports the lugs.

• Comprised of precision-manufactured bearings, seals and sensors in one

pre-assembled unit.
• A wheel hub bearing unit is critical to performance, as it affects several
parameters, such as:
• i) the smoothness of the ride
• ii)fuel efficiency
• iii) braking systems
Hub function and application
• The primary function of the hub is to ensure that the wheel of the
vehicle spins freely, while also keeping it attached to the vehicle.
• It plays a crucial role in the safety and handling characteristics of a
vehicle.
• It is integrated with the knuckle which connects the suspension
between the chassis and the wheel.
FE Modelling of Hub
• To simulate this hub, we can use any simulation software such as ANSYS,
CATIA etc. For the purpose of this analysis, we have made use of Ansys
Workbench-Static Structural.
• To model this hub, one has to incorporate the various boundary conditions
based on the loading that the hub undergoes during its operation.
• The selection of the boundary conditions is based on experimentally
determined load values occurring at the key sites on the hub. These are the
i) 6000N cornering load
ii) 4000N frontal impact load.
iii) 8000N bump load.
Meshing & Type of Elements Used
• The versatility of the software ensures that the meshing can be done
automatically, based on the boundary conditions, material used, FoS
and the loads applied.
• The fine tetrahedron mesh is suitable for the analysis. Alternatively,
the settings used for AutoMesh are Maximum Element Size=1, &
Refinement=100.
• The material used for the hub is Al-7 Series, owing to its strength to
weight ratio, availability and relatively lower cost. For Al-7075-T6, the
yield stress is ~512MPa.
First Iteration

• In the first iteration, a

basic design was used
for the hub.
• There were no pockets
given on flanges, and
the flange profile and
construction is simple
in nature.
Second Iteration
Observations & Conclusions
• After multiple iterations, an opt design was obtained, which was light
in weight and met the strength criteria.
• The deformations were found to be minimal and within safe limits.
• As it also met the FoS requirement, this design i.e, the third iteration
was chosen as the final design for the hub.