Design of a styled steel wheel by using topology and shape optimization

Abstract

Steel wheel has a competitiveness more than aluminium wheel at an economical issue because of material price. However, property of steel has a limitation that natural frequency is lower than aluminium. And steel wheel design at styling point has a tendency to be behind the times compared with aluminium wheel. This paper presents conceptual design process for maximizing first natural frequency by using topology and shape optimization. Firstly, topology optimization was implemented on a design variable domain in the disk, and was performed to have 5 spoke patterns for matching the newest styling. Secondly, shape optimization was applied on each spoke by bead generation. Conceptual model was determined in consultation with Hyundai Motor company with maximizing natural frequency. Based on the conceptual model, a revised model was created through manufacturability concerns. Lastly, the final model produced by the Hyundai Motor company was created by the tendency of wheel tendency from shape optimization. And the final model was validated by traffic noise assessment. The first natural frequency of the final model was improved by 150% compared with initial steel wheel model.