Cost reduction of aluminium alloy wheels by failure mode analysis-based mass optimisation

In this study, an aluminium alloy wheel for light commercial vehicles and passenger cars was optimised for mass reduction while maintaining safety standards, and the effects of this change on cost and carbon footprint were evaluated. Cornering fatigue and impact tests validated the existing design’s compliance with standards. Finite Element Analysis (FEA) identified potential mass reduction regions, followed by a Design of Experiments (DoE)-based optimisation, achieving a 23% weight reduction. The final design was also experimentally verified for durability. The cost analysis indicated approximately a 4% reduction in manufacturing expenses per wheel. According to the data obtained from the wheel manufacturer, in accordance with the total production/sales of the relevant wheel at 2026, it has the potential to reach approximately EUR 2.3M in cost savings.