Lightweight design of electric vehicle wheels using ANSYS workbench

Abstract

The global automotive industry is undergoing a transformation toward low-carbon and sustainable development, where new energy vehicles (NEVs) have become the mainstream direction. However, the limited driving range remains the primary factor hindering their market popularization and large-scale application. Lightweight design serves as one of the most direct and effective technical means to improve the driving range of NEVs, reduce energy consumption, and optimize vehicle handling performance. As a critical load-bearing structural component of vehicles, the weight reduction of wheel hubs plays a crucial role in enhancing the overall performance of the entire vehicle. This paper takes the star-spoke shape as the core design element, using 3D modeling software to construct the integral wheel hub structure. Through the optimization of external configuration and structural details, the wheel hub meets the lightweight design standards. Based on the ANSYS Workbench finite element simulation platform, simulations of mechanical properties and dynamic characteristics were carried out for the designed wheel hub under various actual driving conditions. The simulation results show that under typical load conditions, the overall strength, stiffness, and fatigue durability of the wheel hub meet the engineering requirements for practical application and are validated against the national standard GB/T 5334‑2021 and published experimental data. Meanwhile, it exhibits stable dynamic operating performance without the risk of resonance. This study achieves the lightweight design goal while ensuring the structural safety and operational reliability of the wheel hub, providing feasible design ideas and engineering references for the lightweight design and finite element simulation verification of wheel hubs for similar new energy vehicles.