Structural model optimization of bearings-spacer-hub interaction in a racing wheel assembly

This thesis presents the development and optimization of a Finite Element Method (FEM) model aimed at the structural analysis of the wheel assembly of a racing vehicle. The primary objective is to accurately reproduce the mechanical behavior of the system under real operating conditions, with particular attention to bearing preload, contact interactions and the resulting wear phenomena affecting the balls and raceways. The work was carried out in collaboration with the Racing Structural Performance and Design Team at Dallara Automobili. The modeling and simulation activities were performed using Altair’s HyperWorks suite, focusing on achieving both computational efficiency and high-fidelity representation of mechanical interfaces. The model incorporates detailed definitions of contact interactions between components, including preload sources such as nuts, bolts, spacers and wheel fasteners. Each contact was carefully characterized according to stiffness, frictional behavior and geometric tolerances to ensure numerical stability and physical accuracy. The simulations involved different scenarios in which the vehicle works on-track. Preload effects were analyzed in depth, emphasizing their influence on bearing alignment, stiffness and durability. In particular, the study investigated the impact of spacer extra-length and thermal expansion of the upright on preload variations during operation. Various simulation scenarios were developed, including Pretension, Jump, Braking, Cornering and Thermal effects in which loads, constraints and thermal conditions were accurately replicated. The study provided a robust representation of the contact mechanics driving wear and fatigue within the bearings. Overall, the thesis demonstrates a systematic approach to constructing and validating a high-fidelity FEM model capable of predicting preload evolution, structural respons, and the wear mechanisms acting on the bearing balls and raceways under the extreme loads typical of motorsport applications.