ISSN 2466-4677; e-ISSN 2466-4847
SCImago Journal Rank
2024: SJR=0.300
CWTS Journal Indicators
2024: SNIP=0.77
Research on the influence of new structural materials and manufacturing processes with 3d printing on the reliability of automobile hubs
Authors:
, Vladimir Aleksandrovich Zorin1
Received: 23 July 2025
Revised: 3 October 2025
Accepted: 21 October 2025
Published: 15 December 2025
Abstract:
This paper presents the results of modeling and analyzing the influence of new structural materials on the strength and reliability characteristics of automotive chassis hubs using SolidWorks. The possibility of replacing traditional metal materials used in the production of automotive hubs with polymer composite material (PCM) designed with predetermined properties is discussed. During the study, the manufacture of automobile hubs using 3D printing technology was optimized with modern software. The simulation results of three different materials, namely PCM Acrylonitrile Butadiene Styrene / Glass Fiber (ABS/GF), titanium alloy Ti-8Mn and steel C45, using finite element analysis (FEA), showed that the newly developed ABS/GF PCM material based on glass fiber reinforced thermoplastic polymer is more suitable for manufacturing automotive axles than two existing metals, titanium alloy Ti-8Mn and steel C45, thanks to its high strength and being 72.78% lighter than steel C45 and 55.11% lighter than titanium alloy Ti-8Mn. The design of the automobile hubs was optimized using 3D modeling and FEA. Tests demonstrated the high strength and durability of the new material, making it promising for all-weather operation under real road and traffic conditions.
Keywords:
Polymer composite materials, Automobile hubs, 3D printing, Additive technologies, Finite element analysis, Reliability
References:
[1] V. A. Zorin, B. V. Thanh, Study of the influence of new structural materials and hub assembly manufacturing processes on the reliability and safety of the automobile. VIII International scientific conference (FRITME-2024) – Fundamental research and innovative technologies in mechanical engineering, 19-20 November 2024, Moscow, pp.83-85.
[2] A. Maknickas, O. Ardatov, M. Bogdevičius, R. Kačianauskas, Modelling the Interaction Between a Laterally Deflected Car Tyre and a Road Surface. Applied Sciences, 12(22), 2022: 11332.
https://doi.org/10.3390/app122211332
[3] Digital notes ‘CAD/CAM’ R15A0331. Department of Mechanical Engineering, Malla Reddy College of Engineering & Technology (MRCET), India, 2015.
[4] S.S. Panda, J. Gurung, U.K. Chatterjee, S. Sahoo, Modeling and fatigue analysis of automotive wheel rim. International Journal of Engineering Sciences & Research Technology, 5(4), 2016: 428-435.
https://doi.org/10.5281/zenodo.49728
[5] B. Abhiman, M.Y. Kumar, Optimization of car rim using design and analysis softwares. International Journal of Research in Aeronautical and Mechanical, 9(8), 2021: 01-06.
https://doi.org/10.5281/ZENODO.5270315
[6] R. Kumbhar, S. Pawar, D. Jadhav, N. Dhanrale, Disc Wheel Rim: CAD Modeling and Correlation between FEA and Experimental Analysis. International Journal of Engineering Research & Technology, 3(7), 2014: 1316-1321.
[7] U.S. Maiya, M. Manjunath, S.H. Balakrishna, R.K. Billady, CAD Modelling and Fatigue Analysis of a Wheel Rim Incorporating Finite Element Approach. Universal Journal of Mechanical Engineering, 11(2), 2023: 36-45. https://doi.org/10.13189/ujme.2023.110202
[8] M.V. Chugunov, I.N. Polunina, Optimum design of the metal bellows on the SolidWorks platform. Bulletin of the Mordovian University, 27(2), 2017: 169-177. https://doi.org/10.15507/0236-2910.027.201702.169-177
[9] КОМПАС-3D. АСКОН. (In Russian) https://ascon.ru/products/kompas-3d/ (Accessed: 9 March 2024).
[10] SOLIDWORKS Simulation. Dassault Systèmes – SolidWorks Corporation.
https://www.solidworks.com/product/solidworks-simulation (Accessed: 9 June 2025).
[11] S.I. Shalgunov, D.A. Trofimov, V I. Sokolov, I.D. Simonov-Emelyanov, Model, analysis of 3D structure and method for calculating the physical and mechanical characteristics of reinforced polymer composite materials. VI-Russian Scientific and Technical Conference – Polymer Composite Materials and New Generation Production Technologies, 18 November 2022, Moscow, pp.6-19. (In Russian)
[12] V.A. Zorin, B.V. Thanh, Research of the influence of new structural materials and manufacturing processes on the reliability of the automobile hubs. Bulletin of the Moscow State Automobile and Road Technical University (MADI), 2(81), 2025: 34-42.
[13] I.A. Magomedov, Z.S. Sebaeva, Comparative study of finite element analysis software packages. Journal of Physics Conference Series, 1515(3), 2020: 032073. https://doi.org/10.1088/1742-6596/1515/3/032073
[14] V. Nikolić, Ć. Dolićanin, M. Radojković, E. Dolićanin, Stress distribution in an anisotropy plane field weakened by an elliptical hole. Tehnički Vjesnik, 22(2), 2015: 329-335. https://doi.org/10.17559/TV-20131102132713
[15] M. Radojković, I. Čamagić, Ž. Šarkočević, P. Živković, Z. Golubović, Stress distribution on an isotropic plate with a rectangular opening under biaxial tension load. Structural Integrity and Life, 21(1), 2021: 91-94.
[16] M. Radojković, B. Stojanović, S. Milojević, D. Marić, S. Savić, A. Skulić, B. Krićic, Square Openings as Sources of Stress Concentration in Parts of Machines and Devices. Tehnički Vjesnik, 30(2), 2023: 474-480. https://doi.org/10.17559/TV-20220603080026
[17] A. Jadhav, V.S. Jadhav, A review on 3D printing: An additive manufacturing technology. Materials Today: Proceedings, 62(4), 2022: 2094-2099. https://doi.org/10.1016/j.matpr.2022.02.558
[18] D.A. Varakin, V.A. Zorin, I.S. Nefelov, The influence of slicer program parameters on the quality of machine parts manufactured using additive technologies. High Technologies in the Construction Complex, 1, 2024: 42-47. (In Russian)
[19] Under The Hood: Exploring Automotive Components and Materials. Ochre Media. https://www.automotive-technology.com/articles/exploring-automotive-components-and-materials (Accessed: 9 June 2025).
[20] V.A. Zorin, Engineering Technology, Production and Repair of Lifting, Construction, and Road Machines. Academy, Moscow, 2010.
[21] S.L. Bazhenov, Mechanics and Technology of Composite Materials. Intellect, Dolgoprudny, 2014.
[22] N.I. Baurova, V.A. Zorin, Use of Polymer Composite Materials in Manufacturing and Repair of Machines. MADI, Moscow, 2016.
[23] I.M. Morozov, Fundamentals of Assembly Technology in Mechanical Engineering. Publishing House of Bauman Moscow State Technical University, Moscow, 2006.
[24] Composites of the 21st Century: Opportunities and Reality. Neftegaz.RU. https://magazine.neftegaz.ru/articles/pererabotka/504745-kompozity-21-veka-vozmozhnosti-i-realnost/ (Accessed: 20 July 2024).
[25] X. Tian, A. Todoroki, T. Liu, L. Wu, Z. Hou, M. Ueda, Y. Hirano, R. Matsuzaki, K. Mizukami, K. Iizuka, A.V. Malakhov, A.N. Polilov, D. Li, B. Lu, 3D printing of continuous fiber reinforced polymer composites: development, application, and prospective. Chinese Journal of Mechanical Engineering: Additive Manufacturing, 1(1), 2022: 100016. https://doi.org/10.1016/j.cjmeam.2022.100016
[26] F. Ning, W. Cong, J. Qiu, J. Wei, S. Wang, Additive manufacturing of carbon fiber reinforced thermoplastic composites using fused deposition modelling. Composites Part B: Engineering, 8, 2015: 369-378. https://doi.org/10.1016/j.compositesb.2015.06.013
[27] L. Sannihith, J.K. Babu, B. Rakesh, M.S. Reddy, S. Sripathy, Design and Analysis of Two-Wheeler Wheel Rim with Different Alloy Materials and Loading Conditions. International Research Journal of Engineering and Technology, 9(4), 2022: 112-118.
[28] T.C. Chi, Modeling Static analysis Wheel rim Automobile Using FEA. TNU Journal of Science and Technology, 229(10), 2024: 100-106. https://doi.org/10.34238/tnu-jst.9952
[29] D.C. Planchard, Engineering Design with SOLIDWORKS 2020. SDC Publications, 2020.
[30] E. Desnica, M. Đurđev, B. Vaščić, R. Turmanidze, P. Dašić, Determination of a Safety Factor of a Car Wheel Rim Using Finite Element Analysis in Solidworks. Applied Engineering Letters, 7(4), 2022: 163-171. https://doi.org/10.18485/aeletters.2022.7.4.4
[31] E.E. Kader, A.M. Abed, M. Radojković, S. Savić, S. Milojević, B. Stojanović, Design of a Copolymer-Reinforced Composite Material for Leaf Springs Inside the Elastic Suspension Systems of Light-Duty Trucks. Journal of Composites Science, 9(5), 2025: 227. https://doi.org/10.3390/jcs9050227
[32] M.F. Aslam, A study of correlation between finite element analysis and experimental modal analysis in structural dynamic analysis. Technical Report, 2018. https://doi.org/10.13140/RG.2.2.28632.60162
[33] B. Bastin, S. Adars, A. Madhu, A. Krishnan, B. Jose, P. Raj, Finite Element Analysis of Wheel Rim Using Abaqus Software. International Journal of Engineering Research and Applications, 7(2), 2017: 31-34. https://doi.org/10.9790/9622-0702013034
© 2025 by the authors. This work is licensed under a Creative Commons Attribution-NonCommercial 4.0 International License (CC BY-NC 4.0)
How to Cite
V.Т. Bui, V.A. Zorin, Research on the Influence of New Structural Materials and Manufacturing Processes With 3D Printing on the Reliability of Automobile Hubs. Applied Engineering Letters, 10(4), 2025: 183-192. https://doi.org/10.46793/aeletters.2025.10.4.1
More Citation Formats
Bui, V.Т., & Zorin, V.A. (2025). Research on the Influence of New Structural Materials and Manufacturing Processes With 3D Printing on the Reliability of Automobile Hubs. Applied Engineering Letters, 10(4), 183-192. https://doi.org/10.46793/aeletters.2025.10.4.1
Bui, Van Thanh, and Vladimir Aleksandrovich Zorin. “Research on the Influence of New Structural Materials and Manufacturing Processes With 3D Printing on the Reliability of Automobile Hubs.“ Applied Engineering Letters, vol. 10, no. 4, 2025, pp. 183-192. https://doi.org/10.46793/aeletters.2025.10.4.1
Bui, Van Thanh, and Vladimir Aleksandrovich Zorin. 2025. “Research on the Influence of New Structural Materials and Manufacturing Processes With 3D Printing on the Reliability of Automobile Hubs.“ Applied Engineering Letters, 10 (4): 183-192. https://doi.org/10.46793/aeletters.2025.10.4.1
Bui, V.Т. and Zorin, V.A. (2025). Research on the Influence of New Structural Materials and Manufacturing Processes With 3D Printing on the Reliability of Automobile Hubs. Applied Engineering Letters, 10(4), pp. 183-192. doi: 10.46793/aeletters.2025.10.4.1.
