Abstract: Heavy vehicle have a lot of transmission and action components, it can reduce weight of components effectively to use of aluminum hubs and rims instead of the original steel components. Due to toughness, elastic modulus and fatigue strength of high strength aluminum alloy is low, so it’s a key problem that meets mechanical properties and ensure security. On the basis of the numerical simulation and experimental study, the design guidelines of equivalent static toughness are established that match material properties and structure dimensions. Research shows that using a new manufacturing process and forming method the structure, the strength and toughness of components is improved at the same time. The results show that the static toughness of new component can reach the level of the original components. Aluminum rim weight reduction is more than 55%, aluminum hub weight reduction is more than 60%, and its safety coefficient is 3.57, which is more than defined value 3. The test shows that the aluminum alloy transmission and action components can meet the requirements. The key issues are resolved that using high strength aluminum replaces steel for heavy vehicle hub and rim, at the same time, which provides a design theoretical foundation of “Aluminum instead of steel” for other vehicle component.

Key words: Equivalent static toughness, Lightweight, Static toughness, Transmission and action component