The existing car model wheel rim is drawn in the design software Creo 2.0 and various loads and forces are theoretically calculated and applied on the model and analysed through ansys (17.0) software. Initially the static analysis and dynamic analysis is done by giving the corresponding engineering data that consisting of mechanical properties and their related chemical compositions, the vonmises stresses, deformations, and shear stresses are determined for the complex loading that has been applied on rim models. The complex loading includes applying the pressures ie, 90o angle pressure (inflation pressure) on the bead areas, side thrust on rim flange and the tyre pressure on the well area. And the fatigue analysis which includes the product life, the damage factor and safety factors are determined and all this analysis is done by taking three different designs of the same model of car (Volkswagen polo 1.0 TSI) and rim materials (aluminium, A356-T6, magnesium, MgAm60, titanium, 6Al4V) are changed in each case to know the best design and best material for a particular type of loading and later fatigue analysis is also carried for the same cases to know which design and material will be more durable. From the conclusions of the above analysis we came to know that aluminium has less deformation and magnesium has more durable life so we defined a new material which is the alloy of the above two materials, ie, aluminium-magnesium 5000 series alloys. This material had the advantages of both the materials and also economically best. From the results obtained by analysing these two new alloys we have more life and fewer deformations for the same loading conditions for the rim model.

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