A thesis by Matteo Bisin (University of Rome Tor Vergata), titled Structural Optimization of an Automotive Wheel Rim Using the BGM Method, has been published. The work investigates the application of Radial Basis Function (RBF) mesh morphing technology in the context of structural optimization, focusing on its ability to perform high-quality shape modifications within an integrated simulation environment.

The case study centers on an aluminum alloy wheel rim provided by Nissan. The objective was to enhance structural performance while preserving the original aesthetic design, following a Design-First approach commonly adopted in automotive engineering.

The optimization process was conducted within Ansys Workbench using Ansys Mechanical, employing RBF mesh morphing to execute controlled, smooth geometric transformations without the need for remeshing. This enabled precise mass reduction while maintaining mesh integrity and computational stability.

The second phase of the study introduced the Biological Growth Method (BGM), a technique inspired by natural growth mechanisms, to achieve stress redistribution. The method operated iteratively through the morphing framework, allowing localized geometric adjustments to align with target stress distributions.

The final results demonstrated a measurable reduction in component mass while keeping stress variations within acceptable limits. The original design language of the rim was preserved, highlighting the compatibility of the optimization process with industrial design constraints.

This research illustrates the effectiveness of RBF mesh morphing as a tool for advanced structural optimization, particularly when integrated with bio-inspired design strategies in a commercial simulation workflow.

🔗 Read the full thesis and presentation here.