Figure 1 shows an aluminum wheel rim of a typical urban vehicle. The rim is usually designed against a number of loading cases such as Accelerating, Break and Cornering etc. In this task you will analyse the rim against break and cornering forces and will create a load combination case. A365.0 aluminium is used to cast the rim.

a) Given that the mass of the car is 1850 Kg and it turns at a radius of 10 m with linear speed at 55 kph, work out:
- The cornering acceleration of the vehicle
- The cornering force acting on the one wheel patch (a car has four wheels)

b) The car decelerates at a steady 3G rate. Work out the magnitude of the break load applied in one wheel.

Suppose that the rim is restrained with five nuts (Figure 2) and a stays uniformly against a flat flange as shown in figure 3. Given that the break and cornering forces are applied uniformly on the entire internal side edge surfaces of the rim is used for the break load while only internal phase will be used for cornering (figure 2), perform the following tasks:

c) Browse through the model and measure different part to have some ideas about the sizes.

d) Apply solid tetrahedron mesh on the part precisely and maintain 90% of the mesh within 1 and 4 aspect ratio.

e) Apply the break load evenly tangent to the specified surfaces and analyse the part. Spot the area with high stress concentration and use stress probe to measure the magnitudes.

f) Given that the tyre patch point is located at 110 mm distance from the outer face of the rim, create a rigid contact to apply the nodal cornering force to the specified internal surface and analyse the part. Spot the area with high stress concentration and use stress probe to measure the magnitudes.

g) Create a load combination case from the loads listed above and analyse the part. Spot the area with high stress concentration and use stress probe to measure the magnitudes.

h) Comment on the results for all loading steps ad explain how the assumption may potentially expose error to the results and contribute to their differences with the reality.