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Design and Analysis of Mars Rover Wheel

Article in International Journal of Innovative Research in Advanced Engineering · July 2024

DOI: 10.26562/ijirae.2024.v1107.03

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 IJIRAE :: International Journal of Innovative Research in Advanced Engineering ISSN: 2349-2163
Volume 11, Issue 07, July 2024 https://www.ijirae.com/archives

Design and Analysis of Mars Rover Wheel

Jelson Dalmeida*
Department of Mechanical Engineering
St Joseph Engineering College, Mangalore, INDIA
dalmeidajel@gmail.com
Freston Shaun Sequeira
Department of Mechanical Engineering
St Joseph Engineering College, Mangalore, INDIA
frestonshaunsequeira@gmail.com
M H Mohammed Abrar
Department of Mechanical Engineering
St Joseph Engineering College, Mangalore, INDIA
abrarmh70@gmail.com
Joyston Crasta
Department of Mechanical Engineering
St Joseph Engineering College, Mangalore, INDIA
joystoncrasta@gmail.com
Publication History
Manuscript Reference No: IJIRAE/RS/Vol.11/Issue07/JYE10083
Research Article | Open Access | Double-Blind Peer-Reviewed | Article ID: IJIRAE/RS/Vol.11/Issue07/JYAE10083
Received: 27, June 2024 | Revised: 10, July 2024 | Accepted: 17, July 2024 | Published Online: 28, July 2024
https://www.ijirae.com/volumes/Vol11/iss-07/03.JYAE10083.pdf
Article Citation: Jelson,Freston,Mohammed,Joyston(2024). Design and Analysis of Mars Rover Wheel. IJIRAE::
International Journal of Innovative Research in Advanced Engineering, Volume 11, Issue 07 of 2024 pages 741-746
Doi:>https://doi.org/10.26562/ijirae.2024.v1107.03
BibTeX Key Jelson@2024Design
Copyright: ©2024 This is an open access journal, and articles are distributed under the terms of the
Creative Commons Attribution License; Which Permits unrestricted use, distribution, and reproduction
in any medium, provided the original author and source are credited
Abstract: This project investigates the design and analysis of Mars rover wheels, crucial components for successful
Martian exploration missions amidst evolving technological advancements. Designed to traverse various surface
conditions, including rocks and sand, the rover wheel incorporates a unique configuration with a leaf spring, enhancing its
performance on challenging terrain. Utilizing advanced CAD and simulation techniques, the proposed design is
comprehensively modelled and analyzed, presenting an innovative advancement in Mars rover wheel performance, and
marking a significant stride in space exploration.
Keywords: Mars rover wheel, Surface conditions, Leaf Spring, Evolving technology
I. INTRODUCTION
Mars, known as the “Red Planet” has captivated space exploration efforts, leading to numerous space missions aimed at
unraveling its mysteries. The Martian terrain poses numerous challenges, such as roughness and the presence of rocks
and dunes. Therefore, developing effective wheel designs and analyzing their performance is crucial to ensure the rover's
mobility, stability, and mission success. Among the missions, Mars rovers have played a vital role in advancing our
understanding of the Martian surface. These rovers have provided us with close-up images, conducted scientific
experiments, and collected data that has significantly contributed to our knowledge of the planet. Reference [1] shows
modelled and analyzed a wheel using different materials such as aluminum-based silicon carbide particles and aluminium-
based titanium fiber. As wheels are a key component of planetary exploration for rovers, the study assessed the radial
stiffness, axial stiffness, torsional stiffness, and deflection stiffness to determine wheel performance under mission stress.
Experimental results indicate that the aluminium-based silicon carbide wheel exhibits superior stiffness characteristics
compared to the aluminium-based titanium fiber wheel, except in terms of axial stiffness. Reference [2] investigated the
development of a single composite leaf spring for lightweight wheel vehicles. The study involved theoretical calculations
to analyze various aspects of the leaf spring, including material properties, factor of safety (FOS), and load-carrying
capabilities. Through these calculations, the design aimed to achieve a balance between weight reduction and structural
integrity, facilitating the creation of a lightweight vehicle design with improved performance, enhanced fuel efficiency,
and greater durability. Reference [3] investigated the stresses and deflection of composite leaf springs, comparing them
to those of steel leaf springs. The study evaluated various materials for the composite leaf springs, including E-glass
Epoxy, Carbon. Epoxy, and Boron Aluminum composites, in contrast to the conventional 55Si2Mn90 steel. Finite
Element Method (FEM) analysis was conducted using Ansys 15.0 software to calculate deflection and von Mises stresses
for the springs. The results demonstrated that leaf springs made from composite materials exhibited comparable strength
to heavy steel springs. Reference [4] explores the utilization of small-wheeled rovers in planetary exploration,
particularly focusing on their application in Mars missions to relieve cost and operational challenges.

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 IJIRAE :: International Journal of Innovative Research in Advanced Engineering ISSN: 2349-2163
Volume 11, Issue 07, July 2024 https://www.ijirae.com/archives
This study aims to enhance the mobility of such rovers by investigating the relationship between wheel shapes and
ground resistance forces the research endeavors to propose wheel designs that minimize ground subsidence when
subjected to ground vibrations. Experimental tests conducted on loose terrain validate the correlation between wheel
shapes and rover mobility, with results indicating improved performance using wheels designed to minimize ground
subsidence. Reference [5] discusses the Rocker Bogie mechanism, comprising a rocker arm and bogie assembly
meticulously designed to enhance stability and adaptability for Mars rover wheels. Theoretical calculations entail
determining wheel dimensions, velocity, and lengths of rocker arms and chassis to ensure optimal rover mobility, stability
on uneven terrain, and traction. Additionally, the paper presents a design addressing critical aspects such as material
selection and fabrication techniques essential for establishing an effective rocker-bogie system. This study demonstrates
the valuable insights gained from ANSYS analysis, which provides insight into the performance and behavior of both the
leaf spring and the wheel. Through analysis of stress distribution, deformation, and safety factors, the design choices were
validated, while areas for improvement were identified. These findings comprehensively understand the project's
performance, laying a foundation for further optimization and refinement efforts. By looking at things like stress and how
they bend, we can see if our design choices are good and find ways to make them better.
II. LEAF SPRING
A. Specifications of the Leaf Spring Model
The geometry of the leaf spring considered in this design and analysis is shown in Figure. 1. The material used
is Magnesium RZ5 Alloy and all corresponding material and design data are presented in Table 1.

Fig. 1 The leaf spring

Table I - MATERIAL DATA

Sl. No. Data Details
1 Number of leaves 1
2 Thickness of leaf 2.5mm
3 Width of leaf 4mm
4 Total full length of spring 70mm
5 Young Modulus 44.1Gpa
6 Poisson’s ratio 0.35
7 Tensile strength ultimate 245Mpa
8 Tensile strength Yield 218Mpa
9 Density 1820 Kg/m-3
B. Strength Calculations
The calculations were performed using established engineering principles and equations relevant to leaf spring design and
analysis. Acceleration due to gravity = 3.71 m/s2
Factor of safety (FOS) = 1.1
Total weight = 24 N
Bending stress, σb =

Deflection, δ =
Were, W = load in N.
L = length of the spring in mm.
b = width of the spring in mm.
t = thickness of the spring in mm.
σ = stress (N/mm2).
E = young’s modulus (N/mm2).

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 IJIRAE :: International Journal of Innovative Research in Advanced Engineering ISSN: 2349-2163
Volume 11, Issue 07, July 2024 https://www.ijirae.com/archives
Table II- THEORETICAL CALCULATIONS
Load (N) Stress (N/mm2) Deflection (mm)
24 100.8 1.122
25 105 1.169
26 109.2 1.216
27 113.4 1.262
28 117.6 1.309
29 121.8 1.356
30 126 1.403
III. WHEEL MODEL

Fig. 2 Wheel model

TABLE IIII- WHEEL MODEL DATA
Part No. Details
Part Name Material Quantity
1 Outer shell Al Alloy, Wrought,6061, T6 1
2 Wheel hub Al Alloy, Wrought,6061, T6 1
3 Leaf spring Magnesium RZ5 Alloy 12
4 Pivot point Al Alloy, Wrought,6061, T6 1
5 Outer shell to leaf Spring bolt Ti-6Al-4V, Annealed 12
6 Wheel hub to leaf spring bolt Ti-6Al-4V, Annealed 12
7 Wheel hub to motor hub bolt Ti-6Al-4V, Annealed 1
8 DC motor Metals 1
A. Wheel Calculations
V=
Were, V = velocity in mm/s.
D = diameter of the wheel.
N = RPM.
TABLE III- WHEEL SPECIFICATIONS
RPM(N) Velocity(mm/s) Diameter(mm)
15 100 127.38
IV. MECHANICAL DESIGN OF THE MODEL
A. CAD Model
The 3D model of the wheel was designed using Autodesk Fusion 360 software.

Fig. 3 Iso-metric view of the model Fig. 4 Front view of the model
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 IJIRAE :: International Journal of Innovative Research in Advanced Engineering ISSN: 2349-2163
Volume 11, Issue 07, July 2024 https://www.ijirae.com/archives

V. FINITE ELEMENT ANALYSIS

In this project, ANSYS software was employed to analyze the leaf spring. The leaf spring geometry was meticulously
modelled within the ANSYS environment, with stresses and forces calculated using ANSYS 2023 R1 software. Due to the
inherent symmetry of the leaf spring, only half of the model was analyzed in ANSYS. The leaf spring geometry was
discretised using a 0.5mm meshing technique, dividing it into numerous small elements to accurately capture structural
behavior. This fine mesh size facilitated a detailed representation of the leaf spring's response to applied loads, allowing
for accurate prediction of stress distribution and deformation patterns. Static structural analysis was performed, with
boundary conditions applied based on operating conditions and material data. The analysis provided insights into the leaf
spring's response to applied loads, evaluating its structural behavior. Total deformation indicated the extent of deflection
and deformation experienced by the leaf spring under given loading conditions. The wheel's structural performance was
analyzed in ANSYS, considering stress distribution and deformation under various loads. We utilized a 2mm mesh size
for detailed modelling, ensuring accurate representation of the wheel's behavior. This analysis offers valuable insights into
the wheel's ability to withstand different conditions, aiding in its optimization for enhanced performance.
VI. RESULTS AND DISCUSSION
A. Leaf Spring
The ANSYS analysis offers valuable insights into the performance and behavior of both the leaf spring and the wheel.
Analysis outcomes, encompassing stress distribution, deformation, and safety factor, validate design choices while
identifying areas for improvement. These results provide a comprehensive understanding of the project's performance,
serving as a foundation for further optimization and refinement efforts. Fig. 5 depicts the static structural model of the
spring, with a 12.5N load applied along FY in the downward direction. To simulate gravity's effect in ANSYS, we apply an
acceleration load of +3.730mm/s². This is because in ANSYS, positive values in the Y component of the acceleration load
correspond to downward gravitational force, ensuring accurate representation of mass movement. Figures 6 to 8 display
the total deformation, safety factor, and equivalent von Mises stress. The theoretical/analytical values closely align with
the simulation results obtained in ANSYS. The results obtained are presented in Table V. The calculations and analysis
were conducted for the cantilever beam setup due to its inherent symmetry in nature. For the simply supported beam
configuration, the values can be derived by doubling those obtained for the cantilever beam. Therefore, the bending
stress being lesser than the allowable stress up to 25N (where the bending stress should be lesser than the allowable
stress for the design to be safe) indicates that the design is safe. However, beyond 25N, it fails to meet the safety criteria.

Fig. 5 Static structural Fig. 6 Total deformation

Fig. 7 Factor of safety Fig. 8 Equivalent von-mises stress

TABLE V- RESULTS OBTAINED
Load (N) Analytical Software simulation
Stress (N/mm2) Deflection (mm) Stress (N/mm2) Deflection (mm)
24 100.8 1.122 98.35 0.9398
25 105 1.169 107.73 0.9598
26 109.2 1.216 112.04 0.9982
27 113.4 1.262 116.55 1.0367
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 IJIRAE :: International Journal of Innovative Research in Advanced Engineering ISSN: 2349-2163
Volume 11, Issue 07, July 2024 https://www.ijirae.com/archives
28 117.6 1.309 120.66 1.075
29 121.8 1.356 124.97 1.1134
30 126 1.403 129.27 1.1518
B. Wheel
The structural integrity of the wheel design was thoroughly examined through a static structural analysis using ANSYS,
facilitating a comprehensive evaluation of its performance under loading conditions, including stress distribution,
deformation, and other critical parameters. By conducting static structural analysis, we gained detailed insights into how
the wheel responds to loading scenarios. The wheel model was carefully meshed with a 2mm mesh size in ANSYS as
shown in Fig. 9, ensuring precise representation of geometry, and capturing structural behavior (Fig. 14) with sufficient
accuracy to assess stress distribution, deformations, and other relevant mechanical responses. The analysis enabled
evaluation of stress distribution, deformation, and safety factor, contributing significantly to the overall assessment of the
wheel's performance. Fig. 9 to 14 depict wheel simulation under loading conditions, illustrating equivalent von mises
stress and the factor of safety.

Fig. 10 Factor of safety

Fig. 9 Meshing of the wheel

Fig. 11 Deformation Fig. 12 Equivalent von-mises stress

Fig. 14 Static structural

Fig. 13 Equivalent von-mises stress
VII. CONCLUSION
This paper presents a simplified approach to understanding the design and analysis of Mars rover wheels, contributing to
advancements in planetary exploration. Through research and simulations, we have developed a durable wheel design
that enhances traction and optimizes weight. The utilization of magnesium R5 alloy for the leaf spring material
demonstrates its potential as a favourable choice. Simulation results indicate a close alignment between analytical and
simulated outcomes, affirming the suitability of this material. While our findings aid space agencies in improving rover
mobility, more research is needed for areas like wheel damage prevention and advanced navigation algorithms.
REFERENCES
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Japan, 2019, pp. 331-335, doi: 10.1109/ICARM.2019.8833714.
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IJIRAE: ©2014-24, AM Publications, India - All Rights Reserved https://doi.org/10.26562/ijirae Page - 745
 IJIRAE :: International Journal of Innovative Research in Advanced Engineering ISSN: 2349-2163
Volume 11, Issue 07, July 2024 https://www.ijirae.com/archives
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