The objectives of this research were to study the stress intensity in run-flat metal wheels and to design a new type of run-flat wheels that can be used in a small armored regular truck. Experimental methods and finite element methodologies were applied in the research process. The results obtained by comparing the strain values from the two methods demonstrated the consistency of both methods. The differences in stress values were in 10 -16 percentages which could confirm the capability to analyze the stress distribution and deformation of run-flat by a finite element method. Proven processes and procedures in Pre-processing with SolidWorks Simulation were utilized to design run-flat wheels and a reverse engineering process was next used to create wheel rims and design the cross-sectional shape of new run-flat wheels made of composite materials which have an important reactant; a polymer group and aluminum oxide powder added to enhance the strength. The designed parameters consisted of 1) the width of the run-flat wheels 2) the internal and external radius in which the internal radius depending on the size of the wheel rim and the outer radius which is a variable that determines the height of the run-flat wheels 3) the design of a lockset for tightening the run flat wheels to the wheel rims 4) materials used in the structure of the run-flat wheels and 5) tire pressure. The run-flat wheels designed and built into three-piece parts were designed for ease of wheel assembly or disassembly out of the wheel rims. By analyzing the intensity of stress accumulated in a conventional run-flat wheel (run-flat metal wheel) the stress generated in a run-flat wheel did not exceed the limit of the Yield stress and had a safety value between 3-5 times for new run flat wheels with a maximum stress of 26 MPa. Sizing and cross-sectional dimensions of run flat wheels thus resulted in stress which was in the range that could be withstood and acceptably employed. It was also possible to reduce the height of the flat wheels to make the rear flats lower and increase the width of the run flat wheels which would help distribute more weight to the wheel rims.

Run flat wheels for small armored regular trucks have been re-developed by transformation from the original metallic material to compound materials polymer group materials as important raw materials then added with aluminum oxide powder to achieve higher strength and wear resistance. The research was performed by using reverse engineering processes including designing and analysis with finite element methodology with the SolidWorks Simulation program and comparing the analyzed results with outcome experiments. Several variables used for the design and analysis were 1) the optimal width of the run flat wheel at the parts both attached to the wheel pan and contacted with the inner rubber surface 2) internal and external radiuses. The internal radius is depending on the size of the wheel pan and the external radius is a variable that determines the height of the Run flat wheel. 3) the shape designed to prevent wearing of the inner tire surface of the run flat wheel and the shape of the run flat reel in the part contacted with the wheel pan. This wheel pan part is such uneven inclined area which is difficult to hold. 4) a design locking kit for tightly fastening the run flat reels to the wheel pan 5) the material used to create the run flat wheel and 6) tire pressure. The run-flat wheels were then designed and constructed in a modular form of 3 parts for ease of the wheel pan assembly. In designing pattern the assembling run flat reels had to be fit into the characteristics of a small armored regular truck wheel pan convenient to assemble with a wheel pan and tightly attached without looseness or deformation when impacted. The run flat reel gripping device has been redesigned to lock all three run flat parts together. It brought up the impact resistance from body weight was at 50 km/hr.