Geometrical optimization of aluminum alloy wheels for high fatigue and impact strength

Abstract This study presents a systematic approach to optimizing aluminum alloy wheel geometry to simultaneously improve fatigue life and impact strength while ensuring compliance with ISO 3006 standards. Using finite element method in Abaqus, an optimization methodology was developed that reduces Von Mises stresses in critical spoke and hub regions by 18.7% and 22.4%, respectively. Fatigue life analysis, based on the modified Goodman criterion, demonstrated a 98% increase in cycle life compared to baseline designs. Experimental validation via rotary fatigue and impact testing confirmed the simulation results, with optimized wheels surviving 1.5 × 10 5 cycles without failure. The proposed method enables a 6.2% weight reduction while enhancing mechanical performance, offering significant implications for automotive lightweighting strategies.