Light-Weight Design and Structure Analysis of Automotive Wheel Carrier by Using Finite Element Analysis

It is well known that targeted fuel efficeincy can only be achieved by reducing vehicle weight through improved design and widespread use of lightweight materials. In this study, the weight reduction design process for wheel carriers was carried out through FE-analysis. The von-Mises stress distribution was analyzed by substituting AA6061 (aluminum 6061 alloy) with a tensile strength of 310 MPa instead of FCD600 irons. In the FEA (finite element analysis), stress distribution was performed by applying six chassis load conditions. In addition, the safety factor of the existing FCD600 irons applied wheel carrier was calculated and analyzed to replace AA6061, which is a lightweight material. The approach of this study for predicting safety using safety factor is well established and is expected to be used as a lightweight design guide. In addition, it is expected to contribute to the appropriate design conditions for the development of lightweight wheel carriers for automobiles.