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.

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.