Evaluation method and prediction model of rolling resistance based on deformation characteristics of tire carcass contour

To explore evaluation method for tire rolling resistance, predict rolling resistance and reduce testing costs, this paper proposes an evaluation method and a prediction model of rolling resistance based on deformation characteristics of tire carcass contour. Firstly, a finite element model (FEM) of a 205/55R16 passenger car radial (PCR) tire was established along with a corresponding free-rolling simulation model, to numerically calculate the tire’s rolling resistance. The accuracy of the model and rolling resistance calculation method was experimentally validated through the tire stiffness test, tire static ground contact distribution characteristics test and rolling resistance test which follows ISO 28580 standard. Subsequently, 20 PCR tires with varying structural designs were analyzed to assess their rolling resistance through numerical simulation. During carcass contour deformation, the deformation characteristics of the carcass cord stress were analyzed. Key parameters, including the nodal S11 stress and coordinates of each cord under both inflation and loading conditions, were extracted. From the perspectives of mechanical and geometric properties, the carcass contour deformation parameters were calculated for different design schemes. Then, the correlation between the carcass contour deformation parameters and rolling resistance was investigated using Pearson correlation analysis. The most influential parameters were selected as evaluation metrics, and a rolling resistance prediction model was constructed using Principal Component Analysis (PCA). The results indicate that the derived regression equation demonstrates strong fitting performance, and enables accurate prediction of rolling resistance across different tire structural designs. It should be noted that although 20 tire structures of the 205/55R16 type were selected as fitting variables in this study, this approach provides a theoretical foundation and reference value for evaluating and optimizing tire rolling resistance for other tires. In the future, this methodology can be extended to other tire specifications and larger sample sizes, thereby providing more robust guidance for tire structural design.