ArticleScientific reports2026
Topology optimization of wheel spoke cavities for lightweight design under bending fatigue and impact load cases.
Article in Scientific reports, 2026. The graph could read no effect estimate from its abstract, so it casts no vote on the map. Not yet cited in PubMed.
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Abstract
This paper presents a Multi-Load-Case topology optimization framework for aluminum alloy wheels to overcome the limitations of empirical rear-cavity lightweight designs. To balance structural integrity and mass reduction without altering the aerodynamic outboard styling, a region-constrained topology optimization was conducted. By employing a compromise programming method based on strain energy ratios, the weighting coefficients for bending fatigue and 13° impact load cases were scientifically calibrated. Furthermore, manufacturing constraints, including a 10 mm minimum member size and draw directions, were incorporated to ensure direct compatibility with conventional casting. The results demonstrate that the optimized depth-gradient cavities successfully reduced the peak von Mises stress for bending fatigue by 19.25% (from 133.9 to 108.13 MPa) and for the 13° impact by 14.57% (from 74.63 to 63.76 MPa), alongside a slight mass reduction of 0.53%. This approach offers a mathematically rigorous and industrially viable paradigm for the multi-objective lightweight design of high-performance automotive components.
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