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<p>This paper presents a Multi-Load-Case topology optimization framework for aluminum alloy wheels to overcome the limitations of empirical rear-cavity lightweight designs. To balance structural integrity and mass reduction without altering the aerodynamic outboard styling, a region-constrained topology optimization was conducted. By employing a compromise programming method based on strain energy ratios, the weighting coefficients for bending fatigue and 13° impact load cases were scientifically calibrated. Furthermore, manufacturing constraints, including a 10&#xa0;mm minimum member size and draw directions, were incorporated to ensure direct compatibility with conventional casting. The results demonstrate that the optimized depth-gradient cavities successfully reduced the peak von Mises stress for bending fatigue by 19.25% (from 133.9 to 108.13&#xa0;MPa) and for the 13° impact by 14.57% (from 74.63 to 63.76&#xa0;MPa), alongside a slight mass reduction of 0.53%. This approach offers a mathematically rigorous and industrially viable paradigm for the multi-objective lightweight design of high-performance automotive components.</p>

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Topology optimization of wheel spoke cavities for lightweight design under bending fatigue and impact load cases

  • 期刊论文

  • 出版模式：

    开放获取

  • 发表日期：

    2026年3月28日

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  • Guangdong Zhang,
  • Xin Cui,
  • Yongxing Zang,
  • Yangyang Zhou,
  • Jianjun Lu,
  • Zhansheng Li,
  • Haitao Yang,
  • Jiandong Wang,
  • Zhen Ye,
  • Risheng Li,
  • Linzhen Zhou

摘要

This paper presents a Multi-Load-Case topology optimization framework for aluminum alloy wheels to overcome the limitations of empirical rear-cavity lightweight designs. To balance structural integrity and mass reduction without altering the aerodynamic outboard styling, a region-constrained topology optimization was conducted. By employing a compromise programming method based on strain energy ratios, the weighting coefficients for bending fatigue and 13° impact load cases were scientifically calibrated. Furthermore, manufacturing constraints, including a 10 mm minimum member size and draw directions, were incorporated to ensure direct compatibility with conventional casting. The results demonstrate that the optimized depth-gradient cavities successfully reduced the peak von Mises stress for bending fatigue by 19.25% (from 133.9 to 108.13 MPa) and for the 13° impact by 14.57% (from 74.63 to 63.76 MPa), alongside a slight mass reduction of 0.53%. This approach offers a mathematically rigorous and industrially viable paradigm for the multi-objective lightweight design of high-performance automotive components.