Engineering Failure Analysis — published in affiliation with European Structural Integrity Society

William V. Mars, Ph.D., P.E. is a co-author of the article A Preliminary Conceptual Study for Coupled Thermo-Mechanical and Structural Characterization of Rim-Supported Run-Flat Tires which is published in Engineering Failure Analysis Volume 176, 1 July 2025, 109617. The Engineering Failure Analysis journal provides an essential reference for analysing and preventing engineering failures, emphasising the investigation of the failure mechanisms, identifying the failure’s root causes, and proposing preventive actions to avoid failures.

To promote and share this work the publisher, Elsevier, Ltd., is providing 50 days’ free access to the article and we are excited to share this opporunity with you. Anyone clicking on this link before June 17, 2025 will be taken directly to the final version of the article on ScienceDirect, which you are welcome to read or download. No sign up, registration or fees are required.

Thanks and acknowledgments to co-authors: Behzad Hamedi, Abhishek Saraswat, Jeff Warfford, Cameron Garman, William V. Mars, Saied Taheri.

Highlights

• Advanced understanding of tire–insert interactions to improve safety and performance of rim-supported run-flat tires (RSS RFTs) using a 3D coupled thermo-mechanical FEA model.
• Investigated strain distribution, heat generation mechanism, and fatigue life under zero-pressure conditions using Abaqus and Endurica co-simulation.
• Identified critical zones of thermal and structural stress; proposed design improvements to enhance durability and reduce material degradation.
• Optimized insert geometry to minimize thermal hotspots, sidewall warpage, and localized deformation.
• Confirmed model reliability through convergence studies, sensitivity analysis, and consistency with prior research and literature comparison.

Abstract

Rim-supported inserts in run-flat tires (RSS RFTs) ensure extended mobility after a blowout, offering at least 50 miles of operation at 45 mph under zero-pressure conditions. However, excessive heat generation during deflation accelerates rubber aging and degrades performance. To address this, a validated 3D finite element model, coupled with Abaqus/CAE and Endurica co-simulations, is used to analyze strain distribution, contact patch characteristics, and thermo-mechanical behavior.

Results reveal high strain and heat generation concentrated in the contact patch center, intensifying material degradation and the risk of premature failure. Strain redistribution mechanisms, shifting strain from the footprint and inner liner zones toward the sidewall, enhance durability and mobility under repeated loading or deflation scenarios. The methodology optimizes insert designs to mitigate localized stresses, deformation, sidewall warpage, and thermal issues, thereby extending fatigue life in deflated conditions.This study highlights critical design factors influencing the durability and performance of rim-supported run-flat tires (RSS RFTs). Simulation-driven methodologies are employed to evaluate and optimize key parameters such as durability, contact patch footprint area, pressure distribution, radial stiffness, and overall operational efficiency. A nonlinear FEA model in Abaqus/CAE accurately simulates large deformations, material behavior, and tire geometry, validated through mesh convergence studies, sensitivity analyses, and failure mechanism evaluations under diverse loading conditions. Predicted fatigue life and thermal performance align with prior studies, confirming the reliability of the approach and its potential for real-world application.