Wheels India Ltd.

India, India

Wheels India Ltd.

India, India

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Munirathinam C.,Wheels India Ltd. | VImalathithan S.A.,Wheels India Ltd. | Thiyagarajan S.,Wheels India Ltd.
SAE Technical Papers | Year: 2013

The ability to introduce new lightweight materials into vehicles is not as simple like "remove and replace". The direct challenges in light weighting are manufacturing feasibility for design concept and material selection for right application. The execution approaches of automotive lightweight and the design and manufacturing performance of typical parts with the product performance are discussed. Typical case studies and analysis is presented to evaluate the selection and application of the lightweight materials for different application. © 2013 SAE International.


Muthuraj R.,Wheels India Ltd. | Vignesh E.,Wheels India Ltd. | Kannan C.,Wheels India Ltd. | Thiyagarajan S.,Wheels India Ltd.
SAE Technical Papers | Year: 2013

The objective of this project is to reduce the weight of a wheel without affecting its primary functions such as fitment, air flow and fatigue life, the design is made with the concept of variable thickness, meaning reducing thickness wherever the stresses are low and also addressing the failures in the field. However, requirement of a prototype makes the validation process laborious, costly and time consuming. Finite Element Method (FEM) has evolved as a resourceful tool for analyzing various components under a variety of operating conditions. It is being used not only to predict the critical points bearing the highest stress in a wheel, but also to predict its fatigue life. The present study focuses on the design of variable thickness disc and validation of the same using FEM for air flow analysis and Rig testing. The analysis was carried out on existing and proposed designs and the salient features were compared. © 2013 SAE International.


Muthuraj R.,Wheels India Ltd | Badrinarayanan R.,Wheels India Ltd | Sundararajan T.,Wheels India Ltd
SAE Technical Papers | Year: 2011

For the validation of a new design of a wheel, the conventional fatigue tests may not be entirely sufficient. They may give us the success or failure, but they may not help us any further in improving the design. Experimental Stress Analysis (ESA) is becoming increasingly crucial for the validation of any new design of the wheel. One can know the exact stresses acting at a point on the wheel during its operation with the help of ESA, making it very helpful for further upgradation in design. However, requirement of a prototype makes the validation process laborious, costly and time consuming. Finite Element Method (FEM) has evolved as a resourceful tool for analyzing various components under a variety of operating conditions. It is being used not only to predict the critical points bearing the highest stress in a wheel, but also to predict its fatigue life. However, it is still not very reliable due to its deviation from the ESA observations. The present study focuses on the validation of a new design of forged aluminum alloy wheel using ESA and FEM by comparing with the existing design. The analyses using both the methods were compared and correlated using Required Fatigue Strength (RFS) calculation. Copyright © 2011 SAE International.


Ramasamy M.,Wheels India Ltd. | Vignesh E.,Wheels India Ltd. | Thiyagarajan S.,Wheels India Ltd.
SAE Technical Papers | Year: 2015

A "WHEEL" is one of those auto component in a vehicle which necessitates equal attention from safety, ergonomics and aesthetic perspectives. A conventional tube type wheel for commercial vehicles is made of steel with steel side rings (multi-piece construction). In course as headway in wheel design the single piece wheels were developed which used the tubeless tires. These wheels were made available in both steel and aluminum versions. Wherein the aluminum wheels were lighter in weight than steel, aesthetically more appealing and had other significant advantages. Despite the advantages of these tubeless tire wheels, the end user had to invest for both wheels and tubeless tires to replace conventional tube type steel wheels. The retro-fitment calls for higher exchange cost of wheel and tire and this process stands to be more capitalistic to the end user wherein the payback period was longer. To overcome this monetary situation and without renouncing the advantages of aluminum material, the "FORGED HYBRID WHEEL" was developed to be used with tube type tires. This wheel has a basic construction of forged aluminum wheel base and steel side rings for locking the tire. Surface treatment on the mating surface of steel and aluminum ensures the minimal wear in the hybrid construction. This wheel overcomes the investment on tires, since the existing tube type tires can be used while replacement, and offers all the advantages of aluminum usage such reduction in un-sprung mass of the vehicle which leads to weight saving in buses and trucks to around 41 % as a component and around 18 % in net as wheel and tire assembly. Reduction in weight of the steering system through wheel weight reduction lowers the driver fatigue. As a consequence of reduced weight the fuel economy increases on an average 3% to 5%. Higher emissivity of the material of the product results in dissipating heat generated during service faster (almost double that of the steel) thereby improving the tire life still further. Having in view the cost difference between aluminum and steel, the pay back for the investment can calculated to less than a year. Not only with the tires but also this product does a cooler service with other mating parts thereby improving their life and performance. Real time simulation using the road load data also unravels the superior fatigue life of this product as compared with the steel counterpart. Copyright © 2015 SAE International and Copyright © SAEINDIA.


Charles M.,Wheels India Ltd | Sundararajan T.,Wheels India Ltd | Vimalathithan S.A.,Wheels India Ltd | Sudarsan V.,Wheels India Ltd
SAE Technical Papers | Year: 2011

Manufacturing processes play a major role not only in the attainment of high product quality, but also in the reduction of manufacturing and consequently also product costs. In manufacturing industries tools used are of major importance in this respect, as it is very expensive and critical in the process since it is tool dominant process and their job to convert products or components. In mass productions, wear and chipping of tools is inevitable. Hence reconditioning of tools play vital role since it is not possible to discard the tools for minor damages or flaw, as the tool cost is very high and expensive. However there are variables to consider geometry, material, defect and coating all play a part in driving the decision to recondition a tool. The processes generally used for reconditioning of tools are welding overlays, grinding, machining and using it for next applicable size etc. There tend to be disadvantages like haz softening, tool reusable after repeated grinding, chipping off, lesser life etc. The latest trend or new techniques used for the reconditioning of tools is plasma transfer deposition or powder plasma welding (PPW) with the appropriate selection of proper powder composition. It is a process that deposits very precise coatings of perfectly controlled alloys on mechanical parts that are subject to intense wear, significantly extending their service life. We have attempted the reconditioning of our tool using Co-Cr based alloys with the hardness of 70 HRC. The PTA coating not only yielded the better overlays than the base tool but also increased the forming characteristics by producing the part aesthetically better. The process given the way to recondition the tool for more than 3 times and life of the tool become indefinite. Copyright © 2011 SAE International.


Patent
Wheels India Ltd | Date: 2012-02-14

In view of the foregoing, an embodiment herein provides a method of manufacturing wheel disc, wherein said method comprising of steps providing a rectangular strip made of metallic materials, circling the strip to form a band, welding the band to form a hoop by welding process, forming one side of the hoop to make the centre portion of the disc, spinning another side of the hoop to form flange of the disc, and achieving varying thickness across the disc to make variable thickness wherever needed, thereby reducing the usage of raw material and reducing wastage and making light weight wheel disc.

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