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International Journal of Pure and Applied Mathematics Volume 118 No. 9 2018, 331-343 ISSN: 1311-8080 (printed version); ISSN: 1314-3395 (on-line version) url: http://www.ijpam.eu Special Issue ijpam.eu

A REVIEW ON SELECTION, MANUFACTURING AND TESTING OF COMPOSITE MATERIALS FOR ChintalaSaiVirinchy*, Abdul HafeezAsif, V. Jayakumar, D.Santhosh Kumar, MarrireddyRaviteja Reddy Department of Mechanical Engineering, Saveetha School of Engineering, Saveetha Institute of Medical and Technical Sciences, Chennai – 602105, Tamil Nadu, INDIA

ABSTRACT The wheels of an automobile are usually made out of but due to the increased demand for peculiarity and enhanced outlook alloy materials are used for the wheels these days. Performance of the vehicle is enhanced as they reduce its weight, increase its fuel efficiency and give a spectacular look compared to that of normal steel wheels. But there are some factors which hinder their mass usage like, comparatively high cost and less strength compared to that of steel. Though alloy materials are strong enough if the undergoes significant trauma the alloy rims can bend. Many researchers have been carried out based on enhancing the geometry of the beam, like slightly curved beams could employ more behavioural changes and increased stiffness and some have done research on the structure which concluded bi-directional fabrics could be more efficient and some changes can be made because of changes in cross section. In this paper, a detailed study is carried out on the various parameters, which contribute to the creation of a new composite material for alloy wheels, which include the selection of materials, failure techniques, and the manufacturing processes involved. The main aim is to focus on the advantages, disadvantages and properties of the materials, which are in existence for the purpose of alloy wheels and to understand the loopholes and the possible new outcomes if these limitations can be resolved. Key Words: Alloy wheels, Composite materials, Vibration analysis.

1. INTRODUCTION The selection of a composite material for the purpose of an alloy is as vital as knowing the wheel geometry for its fabrication. In the past years, an optimal effort is being put for the conservation of natural resources. In the recent years, the manufacturers are mainly focused on reducing the weight of the members and are in search low cost, high strength to weight ratio materials. Many benefits and drawbacks may be perceived in a trail of work composite structures for standard antimonial structures. The foremost advantages of a material is that its high strength to weight quantitative relation with unceasingly decreases travel of value

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additionally to different benefits like high specific strain energy storage capability, fatigue strength, superior torsional buckling and glorious corrosive resistance.

2. LITERATURE REVIEW This section in essence presents the survey carried out on the developments related to the novel composite material over the past decades. Particularly the survey is focused on producing a material with high damping coefficient in relation to the structural construction properties that influence their physical, chemical as well as mechanical properties.For the better understanding, the study has been categorized into three sections viz. (i)based on the material selection, (ii) based on the experimental results of various materials, and (iii) based on the testing techniques. 2.1. Based on Material Selection Anushaet al. [1] focused on suggesting a new composite material AZ91E-

2% Al2O3 to the alloy wheels. The ANSYS software is used to carry out the static and impact analysis. And the results proved that a new proposed composite material is a liable replacement for alloy wheels. The results were produced only for the proposed alloy but there was no comparison done with respect to other materials. Santhosh Kumar et al. [19]did analysis and design optimization of Automotive Wheel . Three materials , steel alloy and alloy were used in his study. The author conducts a study on 5 spoke wheel and concludes that Aluminium is the best among the all three materials used. The results are concluded with the help of finite element analysis. The comparison between the magnesium and aluminium alloy was analysed but no comparison of result is done for the existing and the new wheel geometry. Daniel Antonyet al. [2] used a new composition material in their study. The Aluminium alloy PEEK (Polyether ether ketone) with 30% glass fiber and a comparative study for PEEK-90 HMF 40 was carried out, the analysis was carried out to determine displacements and safe stresses using NX NASTRAN software, and results were obtained. The study was limited only to a particular material and a particular design. Ganesh et al. [4] carried out a study on Al 356.2 aluminium for spiral wheel rim used for four-wheel vehicle his paper concluded that magnesium rims are strong enough but not suitable for off road vehicles and also there are not repairable if it is bent yet these were used in Mercedes-G car models. The study can be further extended on the enhancing the properties of wheel. Kale et al. [8] did research on various materials for different wheel rims and concluded that if the requirement is to obtain aesthetics shape with excellent design and

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with very good heat dissipation without compromising on the cost associated then material like aluminium and magnesium alloys can be used for Wheel rims but for off road vehicles like tractor trolley and harvesters state C100 and the forged Steel all the best materials. SrinivasaRao et al. [24] studied about the properties of materials and analysed the results they concluded that simple rim design was more promising and steel alloy was the best material followed by Al & Mg and also summarised that a new material which is an alloy of Al & Mgi.e., aluminium-magnesium 5000 series alloys has best properties and is economically best. Meghashyam et al. [13] concluded that forged steel is the best material after they observe the results if both modal and static analysis. Deflections were more in aluminium and more stress was induced compared to that of forged steel and forged steel was concluded as the best material for designing wheel rim. The Aluminium automotive manual [27] has a well versed study about the types materials used advantages manufacturing process disadvantages Mechanical properties of materials but it is confined only for aluminium material and do not explain the other types of materials. Karthik et al. [9] studied involves three materials - Aluminium alloy, Magnesium alloy and Titanium alloy. The investigation is conveyed with the greatest load that can be connected on edge. The result observed was that the titanium alloy had the best properties compared with aluminium and magnesium. However, the cost of Titanium alloy is high. Hassan M. EL-Dessouky and Carl A. Lawrence [5]made an endeavour to decide the ultra-lightweight Carbon fiber or thermoplastic composite material utilizing spread low Technology. This strategy was discovered promising to build up an ultraweight material.The study also involves various parameters that are to be analysed for producing an ultra-weight carbon fibre or composite material. 2.2. Based on the Experimental results of various materials Li Jian et al. [10]targeted-on Mg alloy wheel and a groundwork is applied on the factors that influence their forming force. The energy saving impact was exceptional. The results conclusion that the forming force will increase with because the temperature of die and material reduces and increase friction coefficient.Sabari et al. [17]did a comparative study for carbon steel and Al alloys has been dole out on the wheel Rim materials for its deformation with the assistance of FEA models the CAD model was drafted using Solidworks, and analysis was performed byCATIA software system it's concluded with the study the displacement in alloy wheel Rim is over the Steel. The study concerned totally different loading conditions to know the deformation behaviour of wheel Rim Solidworks and Catia software is used to perform design and analysis for a

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specific loading of 25 kN the steel rim distorted double than the alloy wheel the conclusion explicit that the steel wheel Rim extremely absorbed masses that declared that Al alloys was more appropriate. Ramamurthy Raju et al. [15]led investigates weakness life of aluminium composite wheels under outspread loads and assessed the outcomes. The material utilized as a part of this examination is (Al) A352.6-T6 Aluminium amalgam. The exhaustion life is assessed by the age of S-N bend. The security factors that are proposed thus are helpful as forecast for a dependable exhaustion life, when the parts are subjected to a radial fatigue load. Sateesh Kumar Reddy [20] aim is to obtain an Optimal Fibre using stacking sequence and tailoring to design a laminated beam. The aim is to obtain a cantilever beam with maximizing stiffness and with minimum weight, which can improve the characteristics of the material and reduce the cost. Prem. J et al. [14] studies other alloys in parallel with the aluminium alloy. Various parameters like ultimate stress were compared. A parametric model has been intended for four-wheeler compound wheel. The investigation comes about demonstrated that the jolts and surface of the wheels suited the greatest pressure. The examination inferred that aluminum wheel was subjected to less worry when contrasted with that of steel. Saurav Das [23] utilized AlSi7MgO3 aluminum composite wheel to contemplate the outline and weight streamlining of game utility auto wheel edge. As per the examination the magnesium combinations were light in weight, great warmth conductor, gave astounding stylish appearance and furthermore flexibility was less when contrasted and aluminum compound however it was additionally presumed that magnesium edges were not repairable after its twisting. Siva Prasad et al. [22] considered properties of different materials, for example, steel aluminum magnesium carbon fiber was examined and the focal points and impediments were learnt.A similar investigation of aluminum and produced Steel for static relocation von Mises stresses and dynamic uprooting was completed and was discovered that manufactured Steel was the best material for the wheel Rim nearly.ThimmegowdaRangaswamy et al. [28]focuses on power applications, which require optimization of composite . E-glass epoxy material weight savings are done. Generic algorithms are used to reduce the weight of shaft constraints like fundamental natural frequency, torsional buckling capacities, torque transmission our studies. Hence, the study concluded that generic algorithms are effective and efficient in engineering applications. Navthar et al. [16] focuses on stress and displacement that are caused in an automobile rim. It was investigated that smoother outer surface of wheel resulted in further reduction in air resistance they work focuses on the air pressure in fire and its effects when

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the is subjected to radial load the study revealed 191 methods that can be employed to apply a radial load on .

2.3.Based on the Testing Techniques Pawar et al. [3] employed the finite element methods for validating thin-walled composite box beams. The fundamental motivation to display a thin-walled composite box pillar is advancement of weight can be accomplished through it. The examination reasoned that the proposed show was discovered suitable in geometrically nonlinear conduct investigation of thin-walled composite shafts. Hement Patel and Rajesh Kumar Satankar [6]centeredaround disappointment examination of Steel wheel by utilizing limited component technique. The examination assessed that in both the cases Von mises stresses are not as much as extreme quality. The conclusion was that ostensible pressure strategy and incorporated limited component examination were the best and effective strategies to foresee that the steel wheel exhaustion life.Liangmowang et al. [11] did Rotary fatigue test simulation to analyze fatigue life of aluminium wheels. The proposed method improved the life cycle of wheel to over 1.0x105 and also satisfied the design requirement. The results indicated that the weakness area can be protected with the help of fatigue life simulation. The nominal stress method is efficient method to predict aluminium alloy wheels’ fatigue life. Samuel OnoriodeIgbuduand David AbimbolaFadare [18] modelled the automobile aluminium alloy wheel and a comparison was carried out on the loading function under static radial load. The study detailed that for non-run flat tires the CLF and BLF offered greater prospect while run flat tires ELF was most suited. Sunil N Yadav et al. [26] analysed the effect of on fatigue life of wheel Rim of Passenger car using radial fatigue testing. The SAE J328 fatigue testing standard is used in this study. The final result focuses on experimental life calculations of wheel rim were compared with finite element analysis predictions. SurabhParopate et al. [21] carried out Modelling and analysis of a wheel Rim. It is observed that aluminium alloy offered better heat conduction, improvement of heat dissipation from the ; this can reduce the risk of failures. The study included Rotary test, static load FEM model was built. This study concluded that thermoplastic resin is a best recommended material for Wheel Rim but due to high manufacturing cost we are not using the material. Vijay Sekhar et al. [29] studied the fatigue and static analysis of aluminium alloy wheel. The various types of fatigue tests were

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described and the FEA techniques were employed for the analysis. The study showed the deflection of alloy wheel Al 2024 - T351 was much less than that of aluminium A 356.2 alloy wheel. J. Stearns et al. [25] worked on analyzing the stress displacement in wheels and the stress analysis on the automotive wheels is done. The highlights are to understand the influence of radial load and pressure caused due to inflation. The study concluded that the rims tend to ovalize at the point of contact it was observed that maximum displacement was applying at the bead seat. Huiyong Ban et al. [7] studied the flexural behaviour of composite beam and analysed it which contained high strength steel. The study is mostly composed of bare steel structures and a little on composite Steel and concrete structures. The study involved analysis of 19 composite beams the study concluded that the nonlinear deformation behaviour reduced with the increase of steel grade. F. Libonati and L. Vergani [12] employed the methods of thermographic analysis to access the damage caused to composite material. The different failure mechanisms have been elaborated and reasons have been analysed. It was found in the study that mechanical behaviour of any composite material was due to various intrinsic and extrinsic factors.

3. RESULTS AND DISCUSSION The key inferences of the above survey are summarized and presented in Table 1. Table 1. Key Inferences S.No. Author Name Research work Material Application Magnesium Static and Impact 1. Anushaet al. (2017) AZ91E-2% Wheel rim analysis Al2O3 Aluminium Study on 4 spoke alloy, Automotive 2. Santhosh Kumar et al. (2016) wheel Magnesium Wheel Rim alloy and Steel Aluminium Study on PEEK- alloy PEEK Automotive 3. Daniel Antony et al. (2016) 90 HMF 40 (Polyether ether Wheel Rim ketone)

4. Pawar et al. (2012) Validating thin- - Composite

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walled composite beams box beams Aluminium alloy wheel for spiral Alloy 5. Ganesh et al. (2014) wheel rim used Al 356.2 wheels for four-wheel vehicle Study on various

material for C100 and 6. Kale et al. (2015) Wheel rims different wheel forged Steel rims Study mainly focuses on a Automotive 7. Hement Patel and Rajesh Steel Kumar Satankar (2014) failure analysis Wheel Rim of Steel Wheel rim Study on the Aluminium- for high load 8. SrinivasaRao et al. (2017) different material Magnesium carrying properties 5000 series vehicles Study on Automotive 9. Li Jian et al. (2013) Magnesium alloy Magnesium Wheel Rim wheel Study involves Alloy 10. Liangmowang et al. (2011) Rotary fatigue - wheels test simulation Study on Carbon Steel & Automotive deformation of 11. Sabari. M et al. (2015) Aluminium Al alloy wheel rim with Alloys wheels the help of FEA Study on modal Automotive 12. Meghashyam. P et al. and static Forged steel Wheel Rim (2003) analysis

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Study on radial Automotive 13. Ramamurthy Rajuet al. A325.6-T6 (2006) fatigue Wheel Rim Study on Automotive 14. Sateesh Kumar Reddy - (2013) Optimal fiber Wheel Rim Comparison of Automotive 15. Premet al. (2016) Different alloys ultimate stress Wheel Rim Comparison of Automotive Samuel OnoriodeIgbudu loading function Wheel Rim 16. and David AbimbolaFadare Al alloy on aluminium (2015) alloy wheel Study on design Automotive and weight Wheel Rim 17. Saurav Das (2014) AlSi7MgO3 optimization of wheel rim Study on effects Automotive 18. Sunil N Yadav et al. (2013) - of camber angle Wheel Rim Modelling and Automotive analysis of wheel Wheel Rim Aluminium 19. SurabhParopate et al. (2013) rim which alloy includes rotary test Study on Automotive Thermoplastic Wheel Rim 20. Siva Prasadet al. (2014) properties of resin various materials Study on Automotive Al and Forged 21. Aluminium automotive properties of Wheel Rim manual (2011) steel various materials Focused on over Automotive transmission Wheel Rim 22. ThimmegowdaRangaswamy which requires E-glass epoxy et al. (2005) optimization of composite wheel

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rim Automotive 23. Karthik. V et al. (2014) Load Analysis Titanium alloys Wheel Rim Study on fatigue Automotive Al2024 - T351 Wheel Rim 24. Vijay Sekhar et al. (2015) and static and A356.2 analysis Study on stress Automotive analysis and Wheel Rim

25. Stearns. J et al. (2005) displacement of - automotive wheels Study on stress analysis and

26. Navthar et al. (2014) displacement of - Wheels automotive wheels Study on flexural Composite 27. Huiyong Ban et al. (2013) behaviour of Composite steel beam composite beam Focused on ultra- Hassan M. EL-Dessouky Composite 28. and Carl A. Lawrence light weight - beam (2013) carbon fiber Study on Composite 29. Libonati. F and Vergani. thermographic - L(2013) beam analysis

From the above conclusions, it is understood that Aluminium alloy is a best material for alloy wheels. In parallel to it,magnesium alloy has excellent mechanical properties but once it undergoes a significant trauma, it cannot be repaired. Therefore, a new combination of aluminium and magnesium alloys can be a novel composite material for alloy wheels.

4. CONCLUSIONS

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Many investigates have been completed on the utilization of composite materials particularly concerning the determination of materials, failure techniques and the manufacturing process involved. The reason behind these researches is to conserve the natural resources and to enhance the properties of the materials and use them for production. This study focused on finding the best composite material existing for the alloy wheels. Though there are numerous combinations in the market available, there are still some limitations like cost, strength and endurance when compared with the steel wheels. A detailed classification was done in the study to make it easy for understanding the various properties and the limitations that are present using a composite material. Many studies are analyzed and a scope for further development is possible in creating a novel composite material suitable for alloy wheels, which are more durable and economical for mass usage.

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[20]Santhosh Kumar. D, Jayakumar V andShajinMajeed “Modal Analysis and Design Optimization of Automotive Wheel Rim”, Journal of Chemical and Pharmaceutical Sciences, Vol. 10(1), 667-669, 2017. [21]Satheesh Kumar Reddy. P, KancharlaBhargavi, Nagaraju. Ch “Tailoring of Composite Cantilever Beam for Maximum Stiffness and Minimum Weight”, IOSR Journal of Mechanical and Civil Engineering, Vol. 9(5), 65-73, 2013. [22]Saurabh M Paropate and Sameer J Deshmukh“Modelling and Analysis of a Rim”, International Journal of Mechanical Engineering and Robotics Research, Vol. 2(3), 148-156, 2013. [23]Siva Prasad. T, Krishnaiah. T,Iliyas. J. Md and Jayapal Reddy. M “A Review on Modeling and Analysis of CarWheel Rim using CATIA & ANSYS”, International Journal of Innovative Science and Modern Engineering, Vol. 2(6), 2014. [24]Sourav Das “Design and Weight Optimization of Aluminum Alloy Wheel”, International Journal of Scientific and Research Publications, Vol. 4(6), 1-12, 2014. [25]SrinivasaRao. K, Rajesh. M and Sreedhara Babu.G “Design and Analysis of Alloy Wheels”, International Research Journal of Engineering and Technology, Vol. 4(6), 2036- 2042, 2017. [26]Stearns. J, Srivatsan. T. S, Gao. X, and Lam. P. C, “Understanding the Influence of Pressure and Radial Loadson Stress and Displacement Response of a Rotating Body:The Automobile Wheel”, International Journal of Rotating Machinery, 1-8, 2006. [27] Sunil Yadav. N and Hanamapure. N. S “Analyze the Effect of Camber Angle on Fatigue Life of Wheel Rim of Passenger Car by Using Radial Fatigue Testing”,International Journal of Engineering Science and Innovative Technology, Vol. 2(5), 231-239, 2013. [28]The “Aluminium Automotive Manual”, Version 2011, European Aluminium Association, 2011. [29]ThimmegowdaRangaswamy andSabapathyVijayarangan “Optimal Sizing and Stacking Sequence of Composite Drive Shafts”,Materials Science, Vol. 11, No. 2, 133-139, 2005. [30] Vijay Sekhar and Chandra Mouli.A “Static and Fatigue Analisys of Aluminum Alloy Wheel”,South Asian Journal of Engineering and Technology (SAJET), Vol.2, No.1, 95-98, 2015.

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