The objective of this research was to design run flat wheels made of aluminum for passenger cars and investigate the stress strain and deformation of run flat wheels and their components. The original 17 inch run flat wheels were made of AISI 1020 steel with a weight of 11.3 kg per wheel. The main problems were from the high-level weight as well as the untighten connection together with noticed gaps taking place between the run flat wheel and the wheel. Therefore in this study the AISI 1020 material was changed to the Aluminum 6063 T6 material. The Numerical methodology using the finite element program was also chosen to indicate the comparative differences in the strain values engaged at various locations of both run flat wheels and pan wheels. The results obtained from both approaches using SolidWorks Simulation Program uncovered the consistent results of the experiments with a 10-16% difference in strain values. The complicated 17 inch wheel pan model was next built using reverse engineering and employed as a key reference to design the cross-sectional area of the new run flat wheels made of Aluminum 6063 T6. All these two parts could be connected tightly. The SolidWorks Simulation program was employed to design and examine the strength of both designed aluminum run flat wheels made of aluminum and the wheel pan made of 17 inch aluminum alloy to build passenger cars. The finite element model was furthermore applied for the run flat wheels made of aluminum 6063 T6 and it provided run flat wheels composed of 2 light weighted pieces. The stress strain and deformation measured were proven and suggested in the test. The output Von Mises stress did not exceed the Yield stress within the linear elastic limit and 3 times safety integrity value. The results from the study were that the obtained run flat wheels allowed the driver to continuously drive for a further 50 kilometers at a speed of 50 kilometers per hour without losing control. They allowed possible tire repairing or replacing when situated in a safe and convenient location.

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.

This research project aimed to test the mechanical properties and the capability in wear resistance of ultra-high molecular weight polyethylene composite as well as determine the optimal formulation of UHMWPE-based composites which had a main component of aluminum oxide. The developed formula was used in the manufacture of run-flat wheels and thus applied to build run-flat wheels with an understanding of the proper molding conditions under the run-flat wheel forming process. Two materials used in the research consisted of super-high molecular weight polyethylene (UHMWPE) as the base material and the additive of aluminum oxide (Al2O3). The parameters employed in the hot compression process to obtain the specimen for the experiment consisted of compressive force temperature time and the ratio between super-high molecular weight polyethylene and aluminum oxide. The test for mechanical properties consisted of an impact test a hardness test according to the ASTM D2240 standard a tensile test according to the ASTM D638 standard type I and a wear test according to the ASTM G77 standard. The results indicated that a hot compression condition under a pressure of 5 MPa a temperature of 210°C for 90 min and using 5% Al2O3 HTM 30 material caused mixed uneven powder particle sizes between 2 to 5 µm. The tensile test results inferred the yield strength of 20.52 MPa ultimate tensile strength at 29.96 MPa breaking strength at 22.83 MPa elongation at break at 265.8% and modulus of elasticity at 784.46 MPa. The highest hardness was 62 shore D the high impact strength was 586.8 J/m and it was displayed for the wear rate of hot compression specimens made of UHMWPE mixed with 5% HTM-30. Moreover it introduced a coefficient of friction the wear rate and the density of 0.12 8.66E-11 mm3/N.m and 1.2446958 g/cm3 respectively.