BRITISH STANDARD AUTOMOBILE SERIES BS AU 50 2 5c 1996 Tyres and wheels — Part 2 Wheels and rims — Section 5c Specification for road wheels manufactured wholly or partly of cast light alloy for passeng[.]
BRITISH STANDARD AUTOMOBILE SERIES Tyres and wheels — Part 2: Wheels and rims — Section 5c: Specification for road wheels manufactured wholly or partly of cast light alloy for passenger cars Reprodu ced by I H S u n d er l i cen se wi th BSI - U n trol l ed Copy BS AU 50-2.5 c:1 996 BS AU 0-2.5c:1 996 Committees responsible for this British Standard The preparation of this British Standard was entrusted to Technical Committee AUE/4, Tyres and wheels for road vehicles, upon which the following bodies were represented: Agricultural Engineers’ Association Automobile Association British Industrial Truck Association British Pressure Gauge Manufacturers’ Association British Rubber Manufacturers’ Association Confederation of Passenger Transport UK Department of Transport Freight Transport Association Institute of Road Transport Engineers (Inc) Motor Cycle Industry’s Association of Great Britain Ltd Motor Industry Research Association National Tyre Distributors’ Association Retread Manufacturers’ Association Road Haulage Association Ltd Society of Motor Manufacturers and Traders Ltd This British Standard, having been prepared under the direction of the Engineering Sector Board, was published under the authority of the Standards Board and comes into effect on April 996 © BSI 07- 999 Amendments issued since publication First published July 976 Amd No Second edition April 996 The following BSI references relate to the work on this standard: Committee reference AUE/4 Draft for comment 94/71 3765 DC ISBN 80 25 366 X Reprodu ced by I H S u n d er l i cen se wi th BSI - U n trol l ed Copy Date Comments BS AU 0-2.5 c:1 996 Contents Page Committees responsible Inside front cover Foreword ii Scope References Definitions Materials 5 Protection of magnesium alloy castings and finished wheels Tests on completed wheels Documentation Marking Valve holes Annex A (normative) Quality control/test schedule Annex B (normative) Validation procedure Annex C (normative) Conformity of production Annex D (normative) Tyre fitting test Procedure for the introduction of new or modified rim profiles Annex E (normative) Dynamic cornering fatigue test Annex F (normative) Dynamic radial fatigue test Annex G (normative) Impact test Annex H (normative) Testing of finishing systems Annex J (informative) Guidance on certain aspects of wheel attachment systems 11 Figure — Typical wheels Figure — Wheel nomenclature Figure — Valve holes 10 Figure G — Machine calibration method 11 List of references © BSI 07- 999 Reprodu ced by I H S u n d er l i cen se wi th BSI - U n trol l ed Copy Figure G — Wheel impact machine Inside back cover i BS AU 0-2.5c:1 996 Foreword This S ection of BS AU has b een p rep ared b y Technical C ommittee AUE /4 It sup ersedes BS AU 0- : 976, which is withdrawn The increas ed p erformance of p ass enger cars led in the 97 0s to the us e for the road wheels of light alloys , generally of aluminium or magnes ium, which offer a favourab le strength to weight ratio The firs t edition of BS AU - was p ub lis hed in 97 to ensure that the quality of des ign and p roduction was adequately controlled This new edition incorp orates Amendment and Amendment to BS AU 0- : 97 6, and introduces technical changes as follows: — in E a maximum length of moment arm is s p ecified; — in E the value for — in G.3 an additional op tion for the tyre has b een allowed for original È and the exp res sion for R have b een changed; equip ment wheels References to other s tandards have also b een reviewed and, where p oss ib le, are now undated This new edition does not, however, cons titute a full revis ion of the standard Tyre, wheel, rim and valve requirements are given in the following Parts and S ections of BS AU : — Part 1: Tyres; — Section 0: General; — Section 1: Car tyres; — Section 2: Commercial vehicle tyres; — Section 3: Off-the-road tyres; — Section 4: Agricultural tractor and machine tyres; — Section 5: Industrial vehicle tyres; — Section 6: Motorcycle tyres; — Section 7: Moped tyres; — Section 8: Code of practice for the storage of tyres, inner tubes and flaps; — Part 2: Wheels and rims; Section 0: General (including terms and definitions, and construction and workmanship); — — Section 1: (Withdrawn); Section 2: Specification for dimensions of wheel naves and hub centres for commercial vehicles; — — Section 3: Specification for road-wheel nuts, studs and bolts for commercial vehicles; Section 5: Specification for road wheels manufactured wholly or partly of cast light alloy for passenger cars; — Section 6: Specification for road wheels manufactured wholly or partly of light alloy for mopeds and motor cycles; — — Section 7: Code of practice for the selection and care of tyres and wheels for commercial vehicles; Section 8: Code of practice for the selection and care of wheels for passenger cars (including caravans and light trailers); — ii Reprodu ced by I H S u n d er l i cen se wi th BSI - U n trol l ed Copy — Part 3: Valves; — Section 1: Specification for valve dimensions; — Section 2: Tyre valve threads 5V1, 5V2, 6V1 and 8V1 ; — Section 3: Tyre valve threads 9V1, 10V2, 12V1 and 3V1; © BS I - 9 BS AU 0-2.5 c:1 996 — Section 4: Tyre valve threads 8V2, 0V1, 11 V1, 13V2, 5V1, 16V1, 17V1 , 17V2, 17V3, 19V1 and 20V1; — Section 5: Dimensions for ISO core chamber No for tyre inflation valves; — Section 6: Dimensions for ISO core chamber No for tyre inflation valves; Section 7: Code of practice for the selection and care of tyre inflation valves for passenger cars (including caravans and light trailers); — — Section 8: Code of practice for the selection and care of tyre inflation valves for commercial vehicles; — Part 4: Rim profiles and dimensions; — Section : Car rims; — Section 2: Commercial vehicle rims; — Section 3: Off-the-road rims; — Section 4: Agricultural tractor and machine rims; — Section 5: Industrial vehicle rims; — Section 6: Motorcycle rims; — Section 7: Moped rims A British Standard does not purport to include all the necessary provisions of a contract Users of British Standards are responsible for their correct application Compliance with a British Standard does not of itself confer immunity from legal obligations Summary of pages This document comprises a front cover, an inside front cover, pages i to iv, pages to 2, an inside back cover and a back cover This standard has been updated (see copyright date) and may have had amendments incorporated This will be indicated in the amendment table on the inside front cover © BSI 07- 999 Reprodu ced by I H S u n d er l i cen se wi th BSI - U n trol l ed Copy iii iv Reprodu ced by I H S u n d er l i cen se wi th BSI - U n trol l ed Copy blank BS AU 50-2.5c:1 996 5.1 Scope This Section of BS AU 50- specifies performance 5.3.4 wheel loading requirements and methods of test for wheels with the mass supported by a wheel any structural element of light alloy for use on all 5.3.5 passenger cars and three- wheeled motorcycles specific application wheel having an unladen weight greater than 255 kg NOTE Requirements for light alloy wheels for use on three- wheeled motor cycles having an unladen weight less than 255 kg are given in BS AU 50- 5.2 References a wheel designed to meet the specification determined by the vehicle manufacturer 5.3.6 general application wheel a wheel designed so that one basic casting may be 5.2.1 Normative references used for wheels to be utilized for a variety of vehicles This Section of BS AU 50 incorporates, by dated or 5.3.7 undated reference, provisions from other radiological standard publications These normative references are made at the appropriate places in the text and the cited publications are listed on the inside back cover For dated references, only the edition cited applies; any subsequent amendments to or revisions of the cited publication apply to this Section of BS AU 50 only when incorporated in the reference by amendment permanent radiographic record of the basic design of wheel showing the minimum acceptance standard as agreed between the founder and the wheel manufacturer 5.4 Materials or revision For undated references, the latest The materials used to manufacture cast light alloy edition of the cited publication applies, together road wheels shall be such that the performance with any amendments requirements of this standard are met, see Annex A 5.2.2 Informative references This Section of BS AU 50 refers to other NOTE The materials used should preferably conform to either BS 490 or BS 2970, however in order to permit the development and application of alloys not included in the above standards, publications that provide information or guidance other light alloys may be used Editions of these publications current at the time of Cast light alloys, whether or not included in issue of this standard are listed on the inside back BS 490 or BS 2970, shall have suitably specified cover, but reference should be made to the latest chemical compositions, mechanical properties and editions 5.3 Definitions For the purposes of this Section of BS AU 50 the definitions given in BS AU 50- and BS AU 50- other physical requirements which shall be defined and agreed between the founder and the wheel manufacturer with particular attention being given to the influence of age hardening and stress corrosion apply, together with the following Whatever the light alloys used in the manufacture See also Figure of road wheels conforming to this Section of 5.3.1 centre member (disc, spider or spoked) the connection between the vehicle hub and the wheel rim BS AU 50, the inspection and quality control for cast aluminium and cast magnesium alloys shall conform to BS 490 or BS 2970 respectively, including the additional inspection and test procedures for analysis, together with optional 5.3.2 procedures as agreed between the founder and the nave wheel manufacturer central portion of centre member, where the wheel mounting face and fixing features are usually located NOTE In the case of BS 2970: 989 this corresponds to the classification QC/TS (quality controlled to a test schedule) In the case of BS 490: 988 this corresponds to supplementary test code A, with other test codes as agreed in the test schedule 5.3.3 Materials other than cast light alloys used to make offset parts of a composite wheel shall conform to the the distance between the mounting face of the nave and the centre- line of the rim (see Figure ) The distance is termed positive (inset) when the appropriate British Standards (see A.3 ) In making use of such materials, cognizance shall be taken of the compatibility of dissimilar materials mounting face is outboard of the rim centre- line and negative (outset) when inboard of the rim centre- line © BSI 07- 999 Reprodu ced by I H S u n d er l i cen se wi th BSI - U n trol l ed Copy BS AU 0-2.5c:1 996 If suitable British Standard specifications are not available, the requirements for the materials shall be specified and agreed between the founder and the wheel manufacturer 5 Protection of magnesium alloy castings and finished wheels The protective treatment against corrosion shall be applied by the founder and/or the wheel manufacturer All surfaces on magnesium wheels shall be fully protected Tyre fitting test 5.6.4.2 Wheel rim profiles not conforming to the requirements of BS AU 50- shall conform to the criteria for acceptance specified in Annex D 5.6.4.3 Dynamic cornering fatigue test (separate wheel) Wheels shall be subj ected to the dynamic cornering fatigue test described in Annex E, and shall conform to the criteria for acceptance specified in E.4 and E.5 5.6.4.4 Dynamic radial fatigue test (separate Tests on completed wheels wheel) 5.6.1 Design approval Wheels shall be subj ected to the dynamic radial To conform to the requirements of this Section of this standard, wheels shall first have the design validated by test samples, which shall demonstrate conformity to 5.6.4 Any change in detail design or fatigue test described in Annex F, and shall conform to the criteria for acceptance specified in F.4 and F.5 5.6.4.5 Impact test (separate wheel) alloy specification shall be followed by revalidation Wheels shall be subj ected to the impact test Revalidation shall also follow any change in the described in Annex G, and shall conform to the finishing system which results in changes in the criteria for acceptance specified in G.7 and G.8 residual surface stress condition 5.6.4.6 NOTE In the case of wheels for general application, test specimens may be selected, using the procedure described in Annex B 5.6.2 C onformity of production Finishing systems Inboard parts of all wheels, the rim area covered by the tyre, whether polished or not, and any other unpolished areas, shall be protected to conform to the requirements of Annex H A finished wheel (not For sampling rates, see Annex C The minimum test panels) shall be used for the salt spray test rate of testing should be in accordance with the specified in H.2.1 recommendations given in C.1 It shall be the responsibility of the wheel The results of the tests shall be interpreted, and manufacturer and the retailer to include with the re- examined or retesting carried out, in accordance sale of polished wheels a warning of the effects of with the criteria specified in C.2 corrosion on the polished areas, and to make 6.3 Preparation of test wheels recommendations regarding protection Tests shall be carried out on fully- finished wheels NOTE representative of normal production except in those cases where permanent coatings have been applied which cannot be removed by simple chemical processes without damage to the wheels, this Guidance on some aspects of the design of wheel attachment systems is given in Annex J 5.7 Documentation Chemical analysis certificates and/or hot metal coating removal being necessary to permit suppliers’ analysis certificates, chemical analysis penetrant- dye crack detection to be carried out In records, mechanical test records, heat treatment these exceptional cases it shall be permissible to test furnace charts, dimensional records and records of uncoated wheels, provided that the wheels have conformity to the performance tests specified undergone the complete heat- stoving cycle in 6.4 appertaining to all wheels shall be retained applicable to the coating process for a minimum period of years 6.4 Performance requirements 6.4.1 General All wheels manufactured to this standard shall conform to the following performance requirements 5.8 Marking Wheels shall be marked with the following information: a) the number of this British Standard, i e BS AU 50- 5c: 996 1) 1) ; Marking BS AU 50- 5c: 996 on or in relation to a product represents a manufacturer’s declaration of conformity, i e a claim by or on behalf of the manufacturer that the product meets the requirements of the standard The accuracy of the claim is solely the claimant’s responsibility Such a declaration is not to be confused with third party certification of conformity, which may also be desirable Reprodu ced by I H S u n d er l i cen se wi th BSI - U n trol l ed Copy © BSI 07- 999 BS AU 0-2.5 c:1 996 b) the country of origin; The above markings shall be permanent and visible c) the trademark or other means of identification when the wheel is fitted with a tyre of the manufacturer; d) the size of the wheel (including offset) In the case of specific application wheels, including Valve holes The hole provided in the wheel rim to accommodate those supplied as original equipment, these shall the tyre valve shall conform to the dimensions given be marked with the vehicle manufacturer’s part in Figure for clamp- in, snap- in or tube valves number for the model for which the wheel has Particular attention shall be paid to the control of been approved; depth on counterbores and due note taken that, in e) the maximum wheel loading as determined by many standard rim profiles, the counterbore on the the vehicle or wheel manufacturer; outer face may come very close to “breaking f) an indication of the date of production of the wheel through” In this event, consideration should be given to increasing the well depth of the rim profile Figure — Typical wheels © BSI 07- 999 Reprodu ced by I H S u n d er l i cen se wi th BSI - U n trol l ed Copy BS AU 0-2.5c:1 996 Figure — Wheel nomenclature Reprodu ced by I H S u n d er l i cen se wi th BSI - U n trol l ed Copy © BSI 07- 999 BS AU 0-2.5 c:1 996 NO TE S ufficient s p ace s hould b e availab le for acces s ib ility to the valve mouth b y hand and b y tyre p res s ure gauge Additionally, any s p ecific requirements to p ermit fitment of the intended valve typ e s hould b e agreed b etween the s p ecifier and the wheel manufacturer NO TE No s harp edges or b urrs are p ermitted at the rim hole NO TE All faces to b e p arallel NO TE Break all s harp edges NO TE Where wheel p rofiles exceed the minimum dimens ions quoted, no counterb oring is neces s ary Figure — Valve holes © BS I 7- 99 Reprodu ced by I H S u n d er l i cen se wi th BSI - U n trol l ed Copy BS AU 50-2.5c:1 996 Annex A (normative) Quality control/test schedule A.1 Cast material Light alloys, whether or not included in BS 490 or BS 2970, shall have suitable specified chemical compositions, mechanical properties and other physical requirements, which are defined and A.2.3.2 Tensile test bars taken from wheels The position of the test bars machined from the wheels shall be clearly defined on the drawing and the frequency with which they are to be taken shall be specified A.2.3.3 Micro- structure Where this is required to be checked, the agreed between the founder and the wheel micro- structure and type of etchant shall be agreed manufacturer with particular attention to age and the areas and frequency of examination shall be hardening and stress corrosion specified A.2 Tests A.3 Metals other than cast light alloy A.2.1 General A.3.1 The metal preferably should conform to an The following tests are in addition to those specified appropriate British Standard in BS 490 and BS 2970; they shall be carried out at A.3.2 Whether or not a suitable British Standard a frequency and to a minimum standard of exists, a detailed specification shall be drawn up to acceptance agreed between the founder and the include all relevant data and processing wheel manufacturer instructions which shall be submitted to the wheel A.2.2 Non-destructive tests A.2.2.1 Production inspection Each casting shall be subj ected to either a penetrant dye inspection for freedom from linear defects or X- ray examination to ensure conformity to the radiological standard Whichever method is used, there should be cross- checking by the other method at such frequency as to ensure that the level of acceptance is maintained For composite wheels, appropriate inspection procedures shall be employed for components and manufacturer for agreement A.3.3 Tests should be as specified by an appropriate British Standard If no suitable British Standard exists, a detailed schedule shall be drawn up This schedule shall include not only tests relating to materials, but also to features of assembly (e g rivets, bolts and nuts, welding) Annex B (normative) Validation procedure B.1 Application groups their attachments manufactured from materials Light alloy wheels for passenger cars generally fall other than light alloys (see also A.3 ) into two distinct groups, termed “specific A.2.2.2 Penetrant dye The type of penetrant dye used and the inspection procedures shall be specified For frequency of testing see A.2.2.1 A.2.2.3 Radiological inspection A radiological standard of acceptance shall be application” and “general application” Wheels supplied as original equipment (OE) are included in specific application B.2 Design validation procedure B.2.1 Wheels designed for a specific application are usually to a specification agreed by the vehicle manufacturer, a maj or item of this specification established by mutual agreement between the being the maximum static wheel loading Wheels founder and the manufacturer and shall be in the designed for a general application shall also have a form of a permanent reference record for each basic maximum static wheel loading decided by the wheel design of wheel manufacturer Inspection to the agreed radiological standard shall B.2.2 For general application, wheels are usually be carried out either on X- ray film or by fluoroscopy designed so that one basic casting may be used on a For frequency of testing see A.2.2.1 A.2.2.4 Hardness tests Where hardness tests are required, the frequency of variety of vehicles This is generally achieved by making provision for fixing holes to be drilled on a variety of pitch circle diameters (PCDs) testing shall be specified A.2.3 Destructive tests A.2.3.1 Impact test bars taken from wheels The position of the test bars machined from the wheels shall be clearly defined on the drawing and the frequency with which they are to be taken shall be specified Reprodu ced by I H S u n d er l i cen se wi th BSI - U n trol l ed Copy © BSI 07- 999 BS AU 50-2.5c:1 996 In addition, certain manufacturers p roduce wheels It is recommended that the minimum rate of tes ting made from cas tings having a common b as ic nave for each of the tes ts describ ed in and sp ider des ign, b ut the die or p attern equip ment b asic design p roduced s hould b e one wheel 5.6.4 and for each is des igned s o that a range of rim widths and/or p er 000 , excep t in the cases of the tes ts des crib ed offs ets may b e mounted on the nave and s p ider in With this typ e of cas ting it is als o us ual to allow for should b e one wheel p er 00 , and in the case of the 5.6.4.3 and 5.6.4.5 , where the minimum rate 5.6.4.4 , s ome variation of nave thicknes s to facilitate s mall tes t describ ed in changes of offs et, and further additional machining should b e one wheel p er 00 In no cas e s hall the may als o b e carried out inside the wheel to ob tain rate b e less than one wheel p er month neces sary clearances C.2 B.2.3 out in accordance with To facilitate a rational ap p roach to the p rob lems of validating the large numb er of res ultant p ermutations on this typ e of wheel des ign a s p ecial validation p rocedure is detailed in B.3 where the minimum rate S hould failure occur during any one tes t carried 5.6 , the p roduction b atch from which the s amp les were taken s hall b e quarantined and an inves tigation carried out as to the cause of failure If the dimens ional accuracy of B.3 Special validation procedure for general the failed wheel is satis factory then the wheel s hall application wheels b e s ub j ected to an investigation of mechanical and B.3.1 metallurgical p rop erties , the caus e of failure Manufacturers making wheels for general determined and the b atch re- examined If the caus e ap p lication can rationalize the numb ers and typ es of of failure cannot b e determined, then s ix further wheel required to b e tested for b oth des ign wheels shall b e sub j ected to the test which p roduced validation and routine quality control failure If any one of the six fails , the comp lete b atch The p rocedure laid down is as follows B.3.2 shall b e deemed not to conform to this standard D etails of all machining carried out on each variant of the b as ic cas ting des ign s hall firs t b e recorded Analysis of this data will indicate those wheel typ es which may b e exp ected to have the minimum p erformance Thes e will in general b e wheels having minimum metal thicknes s in critical areas , b ut Annex D (normative) Tyre fitting test Procedure for the introduction of new or modified rim profiles D.1 A sp ecimen rim incorp orating the new or modified p rofile s hall b e p rovided for the tyre fitting could als o b e wheels with greater than the minimum tes t s p ecified in thickness b ut having sub s tantial stres s raising features B.3.3 D.2 5.6.4.2 Tyres us ed for this test shall b e rep resentative of thos e p ermitted for the p articular rim s ize, From this analys is, a wheel tes t p rogramme s p ecified in BS AU 0- s hall b e estab lished b y the wheel manufacturer The ob j ect of this p rogramme is to p rove the validity of the des ign analysis and identify in p ractical terms D.3 Tyres s hall b e hand fitted using conventional hand equip ment thos e wheel typ es which demons trate minimum D.4 p erformance lives on the tes t rigs the tyre has b een inflated to the recommended B.3.4 fitting p ress ure Up on comp letion of the test p rogramme, thos e Both tyre b eads s hall b e correctly seated when wheel typ es to b e us ed for des ign validation and D.5 routine quality control shall b e estab lis hed b y the rim without any damage wheel manufacturer and details recorded D.6 B.3.5 Up on s atis factory comp letion of tes ts on the The tyre s hall b e deflated and removed from the After satis factory fitting of all tyres p rovided for the tes t, the rim p rofile s hall b e p ut forward for s amp le wheels , the wheel manufacturer shall record p os s ib le incorp oration into the relevant Part of a p ermanent reference of the tes t res ults ap p roving BS AU all typ es of wheel made from the b as ic cas ting concerned Annex C (normative) Conformity of production C.1 Annex E (normative) Dynamic cornering fatigue test E.1 Equipment The tes t machine shall b e one in which a cons tant In order to verify conformity of p roduction, wheels s hall b e examined and tes ted in accordance with 5.6.4 rotating b ending moment is ap p lied to a wheel through the centre memb er, the rotation b eing ab out the axis of the wheel The length of the moment arm s hall b e not greater than m © BS I 7- 99 Reprodu ced by I H S u n d er l i cen se wi th BSI - U n trol l ed Copy BS AU 50-2.5c:1 996 E.2 Procedure The load arm and adaptor assembly shall be attached to the mounting surface of the wheel using studs and nuts (or bolts) in good condition representative of those used on the vehicle The wheel fixing shall be assembled and manually tightened at the beginning of the test using the procedure as specified by the vehicle and/or wheel manufacturer The mating surfaces of the test adaptor and wheel shall be free of excessive build up of paint, dirt or foreign matter E.3 Bending moment determination The bending moment M (in N · m) shall be determined using the following equation: M = F × (È R + d) × 9.81 where F is the static wheel loading (in kg) (see B.2.1 ); S is a test factor taken as 1.7; È is the coefficient of friction developed between the tyre and the road and is taken as 0.75 for the purpose of this test; d is the offset (in m) (positive for inset wheel, negative for outset wheel): for specific application wheels, the actual value shall be used; for general application wheels, the applicable value which gives the maximum value of M shall be used; R is the theoretical nominal static rolling radius (in m) of the tyre given by the following formula: E.5 Accuracy of applied bending moment The applied bending moment, as determined by a suitable means of calibration, shall be accurate to within ± % of its nominal value throughout both the rotation cycle and the duration of the test Annex F (normative) Dynamic radial fatigue test F.1 Equipment The test machine shall be one with a means to impart a constant radial force which rotates with respect to the wheel F.2 Procedure The tyre selected for this wheel test shall be representative of the tyre specified by the vehicle manufacturer or an appropriate tyre size for the wheel The cold inflation pressure of the test tyre shall be not greater than 455 kPa F.3 Test force determination The test force Fr (in N) shall be determined using the following equation: Fr = F × K × 9.81 where F is the static wheel loading (in kg)(see B.2.1 ); K is a test factor taken as 2.25 F.4 Criteria of acceptance The duration of the test shall be 500 000 cycles with Fr applied At completion of the test, there shall be no evidence of fatigue cracks anywhere on the wheel as indicated by a penetrant-dye test F.5 Accuracy of applied force where D1 is the nominal rim diameter (in m); D2 is the design overall diameter (in m); FR = 0.78 (or 0.70 for CT tyres) The applied test force, as determined by a suitable method of calibration, shall be accurate to within ± % of its nominal value throughout both the rotational cycle and the duration of the test Annex G (normative) Impact test G.1 Equipment The test machine shall be one in which an impact force is applied approximately laterally to the rim E.4 Criteria of acceptance flange of a wheel complete with tyre A suitable form The duration of the test shall be 150 000 cycles with of falling-weight machine is shown M applied diagrammatically in Figure G.1 Alternatively, the At completion of the test, there shall be no evidence striker may form the end of a pendulum, provided of fatigue cracks anywhere on the wheel as that the arm is of lightweight construction and that indicated by a penetrant-dye test the striker face is horizontal at the moment of impact with the rim Reprodu ced by I H S u n d er l i cen se wi th BSI - U n trol l ed Copy © BSI 07-1999 BS AU 50-2.5c:1 996 The wheel shall be mounted with its axis at 13° to where the vertical so that its highest point is presented to the vertically acting striker The wheel mount shall F is the maximum static wheel loading as be attached to the upper surface at the mid-span of specified by the vehicle manufacturer a steel plate of cross section 200 mm × 25 mm (in kg)(see B.2.1 ) having a span of 700 mm Each end of the plate shall G.7 Criteria of acceptance be supported on two compression type natural rubber mounts, in parallel, having the following G.7.1 The wheel shall meet the conditions specified specification: in G.7.2 to G.7.5 G.7.2 There shall be no visible fractures or cracks — hardness 50° Shore; (other than any noted before the test) of the centre member as indicated by penetrant-dye test — diameter 51 mm; G.7.3 There shall be no separation of the centre — uncompressed length 27 mm member from the rim The contact face of the striker shall be 150 mm wide G.7.4 There shall be no sudden total loss of tyre air and not less than 600 mm long with a mm radius pressure (i.e the pressure shall be not less on the long edge which contacts the wheel flange than 90 kPa, 30 s after impact) The mass of the wheel mount shall be 20 kg, the G.7.5 Buckling, cracking or fracture of the rim height shall be 230 mm and the diameter of the base flange or general distortion of the wheel shall not, in shall be 150 mm themselves, constitute a failure G.2 Calibration of equipment With the wheel mount located at the mid-span of the beam, a vertical load of 000 kg shall be applied to the centre of the wheel mount as shown in Figure G.2 The vertical central deflection of the beam shall be 7.5 mm For tolerance see G.8 G.3 Procedure The tyre selected for the test shall be either: a) for wheels specified as original equipment, the smallest section width size approved by the vehicle manufacturer; or b) the smallest nominal section width tubeless radial-ply size specified for the rim in the edition of BS AU 50-1.1 current at the date of production of the wheel (as indicated in accordance with 5.8 f) The tyre shall be inflated to a pressure of 180 kPa G.4 Dropping height The dropping height for the striker weight shall be 230 mm above the highest part of the rim flange in all cases G.8 Accuracy requirements The accuracy of the mass of the striker, the mass of wheel mount, and the height of drop shall be within ± % The accuracy of the calibration load (see G.2 ) shall be within ± % and the specified deflection during calibration shall be within ± 10 % Annex H (normative) Testing of finishing systems H.1 Finishing systems All finishing systems used on wheels shall withstand the tests specified in H.2.1 , H.2.2 and H.2.3 These may be carried out on a test panel (minimum size 150 mm × 100 mm) of the same material and surface finish as used for the wheel, except for the salt spray test (see H.2.1 ), for which it is essential that the test is carried out on a finished wheel H.2 Tests H.2.1 Salt spray test This test shall be carried out in accordance with The striker shall be generally over the tyre and the BS AU 148-2:1969 to condition T 35 for a minimum duration of 96 h, after which there shall be no radiused edge shall overlap the rim flange evidence of corrosion visible to the naked eye, with by 25 mm the exception of highly polished surfaces where G.6 Mass of striker superficial corrosion shall be acceptable The The mass D (in kg) of the striker shall be scratch test damage specified in 4.2.4 of determined using the following equation: BS AU 148-2:1969 need not be applied to the highly D = 0.6F + 180 polished surfaces G.5 Alignment of striker © BSI 07-1999 Reprodu ced by I H S u n d er l i cen se wi th BSI - U n trol l ed Copy BS AU 0-2.5c:1 996 Figure G.1 — Wheel impact machine 10 Reprodu ced by I H S u n d er l i cen se wi th BSI - U n trol l ed Copy © BSI 07- 999 BS AU 50-2.5c:1 996 Figure G.2 — Machine calibration method H.2.2 Flexibility and adhesion This test shall be carried out in accordance with BS AU 48- 3: 969 to groups and On completion of the test, there shall be no evidence of paint lifting H.2.3 Resistance to chipping This test shall be carried out in accordance with BS AU 48- 5: 969 The minimum acceptance level shall be in Annex J (informative) Guidance on certain aspects of the design of wheel attachment systems J.1 Type of fixing Although other forms of attachment may constitute good design practice and be acceptable, these recommendations are limited to multiple nut or bolt attachments having spherical or conical bearing accordance with clause , assessment (slight) of and locating surfaces, or a flat bearing surface with that standard parallel shank location © BSI 07- 999 Reprodu ced by I H S u n d er l i cen se wi th BSI - U n trol l ed Copy 11 BS AU 0-2.5c:1 996 The transition between the threaded and unthreaded portions of a bolt shank or stud should Although both centrally spigotted mountings and non-spigotted mountings are allowed for, the former be designed to reduce stress concentrations is preferred J.3.3 Undercuts should have a mm minimum radius at the root J.3 Thread data J.3.1 Threads should be selected from: J.2 Mounting UNF UNF metric metric 12 class 2B (internal) class 2a (external) ISO 6H (internal) ISO 6g (external) Reprodu ced by I H S u n d er l i cen se wi th BSI - U n trol l ed Copy J.3.2 See BS 1580-1 & BS 1580-2 See BS 3643-2 © BSI 07-1999 BS AU 0-2.5 c:1 996 List of references (see clause 5.2 ) Normative references BSI publications BRITISH STANDARDS INSTITUTION, London BS 1490:1988, Specification for aluminium and aluminium alloy ingots and castings for general engineering purposes BS 2970:1989, Specification for magnesium and magnesium alloy ingots and castings BS AU 50, Tyres and wheels BS AU 50-1, Tyres BS AU 50-1.0:1977, General BS AU 50-1.1:1977, Car tyres BS AU 50-1.1.1:1992, Specification for sizes, loads and inflation pressures BS AU 50-2, Wheels and rims BS AU 50-2.0:1979, General (including terms and definitions, and construction and workmanship) BS AU 50-4, Rim profiles and dimensions BS AU 50-4.1, Car rims BS AU 148, Methods of test for motor vehicle paints BS AU 148-2:1969, Resistance to continuous salt spray BS AU 148-3:1969, Flexibility and adhesion BS AU 148-15:1969, Resistance to chipping Informative references BSI publications BRITISH STANDARDS INSTITUTION, London BS 1580, Specification for unified screw threads BS 1580-1:1962 & BS 1580-2:1962, Diameters ¼ in and larger BS 3643, ISO metric screw threads BS 3643-2:1981, Specification for selected limits of size BS AU 50, Tyres and wheels BS AU 50-2, Wheels and rims BS AU 50-2.6:1983, Specification for road wheels manufactured wholly or partly of light alloy for mopeds and motor cycles © BSI 07-1999 Reprodu ced by I H S u n d er l i cen se wi th BSI - 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