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The paper explains the most important criteria for the design of cast aluminum wheels on examples of recently developed European wheels. The basic differences in material behavior between steel and aluminum, such as fatigue strength, cyclic stress-strain properties and crack behavior are treated. The optimization of the wheel design is based on the fatigue strength of individual wheel sections which is determined through special test fixtures. The final proofout test for adequate fatigue life of the total wheel is established through a programmed test carried out in a new biaxial wheel test machine whereby the load program for testing European wheels represents European service conditions.

The keen competition in the automobile industry has in many cases necessitated the adoption of new manufacturing techniques for vehicle components. Forgings especially are being replaced today by castings and fabricated components. The authors show on the example of a forged front wheel hub how weight savings of up to 30% may be achieved on a standard hub forging. The weight savings are achieved through a design methodology called “Service Strength Analysis,” whereby both structural analysis and testing are done under simulated service loadings. The wheel hub is a highly stressed safety component on which the function of other components such as axles, wheels and brakes depend. Service Strength Analysis allows lightweight design to be carried out without sacrifices of reliability; it also allows an effective evaluation of the influence of new low cost manufacturing techniques on the service strength of parts.