Fatigue and impact analysis and multi-objective optimization design of Mg/Al assembled wheel considering riveting residual stress

Abstract

The multi-material assembled light alloy wheel presents an effective lightweight solution for new energy vehicles, but its riveting connection remains a problem. To address this problem, this paper proposed the explicit riveting-implicit springback-implicit fatigue/explicit impact sequence coupling simulation analysis method, analyzed the fatigue and impact performance of the punching riveting connected magnesium/aluminum alloy (Mg/Al) assembled wheel, and constructed some major evaluation indicators. The accuracy of the proposed simulation method was verified by conducting physical experiments of single and cross lap joints. The punching riveting process parameters of the assembled wheel joints were defined as design variables, and the fatigue and impact performance of the assembled wheel was defined as the optimization objective. The connection-performance integration multi-objective optimization design of the assembled wheel considering riveting residual stress was designed via Taguchi experiment, grey relational analysis, analytic hierarchy process, principal component analysis, and entropy weighting methods. The optimization results of the three weighting methods were compared, and the optimal combination of design variables was determined. The fatigue and impact performance of the Mg/Al assembled wheel were effectively improved after optimization.

Graphical abstract

Keywords

magnesium/aluminum assembled wheel / riveting residual stress / fatigue analysis / impact analysis / multi-objective optimization

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Nomenclature

Abbreviations
AHP	Analytic hierarchy process
BCSLIB-EXT	Boeing’s Extreme Mathematical Library
BFGS	Broyden-Fletcher-Goldfarb-Shanno
DOE	Design of experiment
DOF	Degree of freedom
FE	Finite element
GRA	Grey relational analysis
GRG	Grey relational grade
Mg/Al	Magnesium/aluminum alloy
PCA	Principal component analysis
S/R	Selectively reduced
Variables
B	Comparison judgment matrix
Er(x)	Energy absorption of the rim under the 90° impact condition
SCR-bend(x), SCR-radial(x)	Maximum bending and radial compressive stresses at the rivet, respectively
SCs-bend(x), SCs-radial(x)	Maximum bending and radial compressive stresses at the spoke riveting hole, respectively
STR-bend(x), STR-radia(x)	Maximum bending and radial tensile stresses at the rivet, respectively
STs-bend(x), STs-radial(x)	Maximum bending and radial tensile stresses at the spoke riveting hole, respectively
S13-s(x)	Maximum von Mises strain of the spoke under the 13° impact condition
Wc, Wt	Weight coefficients of the maximum compressive and tensile stresses, respectively
x1, x2	Groove diameter and height of the upper riveting die, respectively
x3	Riveting displacement factor
x4	Extension of the rivet rod
x	Vector of design variables
xL	Lower limits of the vector x
xU	Upper limits of the vector x

Declaration of Interest

The authors declared no potential conflicts of interest with respect to the research, authorship, and/or publication of this article.

Acknowledgements

This work was supported by the National Natural Science Foundation of China (Grant Nos. 51975244 and 51475201). The authors would like to express their appreciations for the fund supports.

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