A manufacturing process for fitting wheel hubs and caps

Abstract

This invention relates to a manufacturing process for fitting wheel hub caps. The invention first forms an initial cap groove in the center of the wheel hub through casting. The initial cap groove includes an initial profile and a conforming profile. This stage eliminates the need for milling, effectively reducing manufacturing complexity. Next, the final structure of the cap groove is formed through a one-time machining process, including a positioning groove, a retaining angle inlet, a cap stop, and an inner stop. The rational design of these parts allows the cap to enter the inner stop through the retaining angle inlet and ensures the cap is securely fixed within the cap groove. This invention is particularly suitable for non-circular wheel hub cap designs, solving the common manufacturing difficulties and high costs associated with such conforming designs. It eliminates the need for new milling equipment, employing a one-time machining process that effectively reduces manufacturing costs and improves production efficiency.

Description

Technical Field

[0001] This invention relates to the field of wheel hub manufacturing technology, and in particular to a manufacturing process for fitting wheel hubs and caps together. Background Technology

[0002] The current market preference for aluminum alloy wheels stems primarily from their excellent performance, recyclability, and aesthetic appeal. As consumer demand for personalization continues to grow, the variety of wheel caps is also increasing. Generally, if a standard round cap is used, the design process mainly involves considering the cap's external dimensions and assembly tolerances, which is relatively simple.

[0003] However, when it comes to non-circular cap designs, profile milling is often required, combined with precision machining using turning. In such cases, new milling equipment is often needed, which not only increases manufacturing costs but also impacts production efficiency.

[0004] Therefore, a new solution is urgently needed to address the manufacturing needs of non-circular hubcaps, in order to improve production efficiency and reduce manufacturing costs. Summary of the Invention

[0005] Therefore, the technical problem to be solved by the present invention is to overcome the problems of high manufacturing cost and low manufacturing efficiency in the processing of non-circular caps for wheel hubs in the prior art.

[0006] To solve the above-mentioned technical problems, the present invention provides a manufacturing process for fitting a wheel hub and a cap. The cap includes: a body, a transition ring extending axially from one end of the body, the transition ring extending from the end away from the body having radially outwardly protruding corners and positioning bosses distributed alternately in the circumferential direction, the corners having a groove on their radially inner side and a retaining spring engaging through the groove, the corners having an outer beveled surface inclined towards the end away from the body and an inner snapping surface inclined towards the end close to the body and extending to the outer beveled surface, a reinforcing rib being provided between the radially inner side of the transition ring and the body, and an avoidance surface being provided on the outer side of the body near the positioning boss.

[0007] The manufacturing process includes:

[0008] An initial cap groove is formed in the center of the wheel hub by casting. The initial cap groove includes an initial profile located on its periphery, and the initial profile includes a cap groove conforming profile.

[0009] The initial surface is machined in one step according to a preset machining path to form a cap groove. The machined cap groove includes a positioning groove connected to the contour surface of the cap groove, and a corner guide, a cap stop, and an inner stop connected in sequence to the positioning groove. The corner guide is constricted along the direction close to the cap stop, and the inner stop is expanded along the direction away from the cap stop. The positioning groove is annular, and the bottom end of the positioning groove is used to axially support the positioning boss. The corner is guided sequentially through the corner guide and the cap stop and enters the inner stop. The retaining spring provides a force to resist the corner against the inner stop to fix it in the cap groove.

[0010] In one embodiment of the present invention, the cap groove does not require milling, the casting deformation tolerance of the casting is ±0.7mm, the groove depth of the placement groove is greater than the casting deformation tolerance, and is more than 1.5mm, and the bottom of the placement groove has a chamfer to increase the space between the cap groove and the inner side of the cap.

[0011] In one embodiment of the present invention, when the maximum diameter of the retaining angle is less than or equal to the maximum diameter of the positioning boss, the retaining angle inlet has an inlet ramp and the inlet ramp is at an angle of 15-45° to the hub center axis. The maximum diameter of the retaining angle inlet is greater than the maximum diameter of the retaining angle but less than the diameter of the body. Alternatively, when the maximum diameter of the retaining angle is greater than the maximum diameter of the positioning boss, a secondary slotting processing and assembly process is adopted. The retaining angle inlet is a concave curve and forms an outer stop with the positioning groove. The maximum radius of the retaining angle inlet is greater than the maximum radius of the retaining angle by ≥0.15mm, the radius of the positioning boss is greater than the radius of the outer stop by ≥0.2mm, and the maximum radius of the retaining angle is greater than the radius of the outer stop by ≤1.2mm.

[0012] In one embodiment of the present invention, the axis of the cap stop is parallel to the central axis of the hub, the diameter of the cap stop is 0.3-0.5 mm larger than the diameter of the transition ring, and the axial length of the cap stop is between 0.5-2.5 mm, so as to reduce the resistance of the cap entering the cap groove, which is less than 5 kgf.

[0013] In one embodiment of the present invention, the inner stop includes an inner inclined surface of the stop that is inclined to the central axis of the hub. The acute angle between the inner inclined surface of the stop and the central axis of the hub is less than 43°, and the obtuse angle between the inner inclined surface of the stop and the central axis of the hub is 3-25° larger than the obtuse angle between the inner buckle surface of the clip and the central axis of the transition ring.

[0014] In one embodiment of the present invention, the inner bevel of the stop and the retaining angle are interference fit, and the interference fit amount is 0.1-0.65mm.

[0015] In one embodiment of the present invention, the gap between the outer surface of the main body and the conforming surface of the cap groove is 0.98±0.6mm.

[0016] In one embodiment of the present invention, the starting point of the machining path is ≥0.17mm larger than the maximum diameter of the cap on one side and falls inside the conforming surface of the cap groove, so as to achieve the purpose of visual error prevention.

[0017] In one embodiment of the present invention, by adjusting the diameter of the cap stop and using a push-pull force gauge to detect the resistance of the cap in the cap groove, the pull-out force is ≥5kgf when the cap stop diameter is ≤75mm, and ≥8kgf when it is above 75mm, so as to ensure that the cap does not fall off when the vehicle is traveling at high speed or bumpy.

[0018] In one embodiment of the present invention, during machining, an internal hook cutter with a principal cutting edge angle of 110° and a 35° rhomboid blade is selected.

[0019] The technical solution of the present invention has the following advantages compared with the prior art:

[0020] The present invention discloses a manufacturing process for wheel hub and cap fitting, which is particularly suitable for wheel hub caps with non-circular designs. It solves the common manufacturing difficulties and cost problems in such designs. The manufacturing process adopts a one-time forming process, which does not require the introduction of new milling equipment, effectively reducing manufacturing costs and making production more economical and efficient. By simplifying the processing flow, the present invention reduces complex steps in the manufacturing process, thereby improving production efficiency and helping to complete the manufacturing of wheel hub caps faster.

[0021] By adjusting the gap between the outer surface of the main body and the conformal surface of the cap groove, this invention successfully optimizes the space between the cap groove and the inner side of the cap, reducing the gap between the wheel hub cap and the casting by about 45% and improving the overall aesthetics.

[0022] In terms of processing path design, this invention improves the accuracy of the process and the visual effect by adjusting the starting point position. Attached Figure Description

[0023] To make the content of this invention easier to understand, the invention will be further described in detail below with reference to specific embodiments and accompanying drawings.

[0024] Figure 1 This is a schematic diagram of the main structure of a cap.

[0025] Figure 2 This is a side view of the structure of a cap.

[0026] Figure 3 This is a diagram showing the installation of the cap in the wheel hub.

[0027] Figure 4 This is a schematic diagram of a cap groove processing method according to the present invention.

[0028] Figure 4a yes Figure 4 A magnified view of a portion of the image.

[0029] Figure 5 This is a schematic diagram of the processed cap groove according to the present invention.

[0030] Figure 5a yes Figure 5 Enlarged view of a part Figure 1 .

[0031] Figure 5b yes Figure 5 Enlarged view of a part Figure 2 .

[0032] Figure 6 This is a schematic diagram showing the fit between the cap and the cap slot.

[0033] Figure 7 This is a schematic diagram of the gap between the cap groove and the cap of the present invention.

[0034] Figure 7a yes Figure 7 Enlarged view of a part Figure 1 .

[0035] Figure 8 This is a schematic diagram of the main structure of another type of cap.

[0036] Figure 9 This is a schematic diagram of another type of cap groove processing according to the present invention.

[0037] Figure 9a yes Figure 9 Enlarged view of a part Figure 1 .

[0038] Figure 9b yes Figure 9 Enlarged view of a part Figure 1 (Cap omitted).

[0039] Figure 10 This is a schematic diagram of the internal hook blade of the present invention.

[0040] Explanation of reference numerals on the accompanying drawings:

[0041] 100. Machining path; 200. Internal hook cutter; 300. Wheel hub;

[0042] 1. Cap; 11. Body; 11a. Clearance surface; 12. Transition ring; 13. Corner; 13a. Outer bevel of corner; 13b. Inner snapping surface of corner; 14. Positioning boss; 15. Slot; 16. Snap spring; 17. Reinforcing rib;

[0043] 2. Initial cap groove; 21. Initial profile; 22. Cap groove conforming profile;

[0044] 3. Cap groove; 31. Positioning groove; 32. Angle guide opening; 32a. Guide slope; 33. Cap stop; 34. Inner stop; 34a. Inner slope of stop; 35. Outer stop. Detailed Implementation

[0045] The present invention will be further described below with reference to the accompanying drawings and specific embodiments, so that those skilled in the art can better understand and implement the present invention. However, the embodiments described are not intended to limit the present invention.

[0046] In this invention, when directions (up, down, left, right, front, and back) are described, it is only for the purpose of describing the technical solution of this invention, and does not indicate or imply that the technical features referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, it should not be construed as a limitation of this invention.

[0047] In this invention, "several" means one or more, "multiple" means two or more, "greater than," "less than," "exceeding," etc., are understood to exclude the stated number; "above," "below," "within," etc., are understood to include the stated number. In the description of this invention, the terms "first" and "second" are used only to distinguish technical features and should not be construed as indicating or implying relative importance, or implicitly indicating the number of indicated technical features, or implicitly indicating the order of the indicated technical features.

[0048] In this invention, unless otherwise explicitly defined, the terms "setting," "installing," and "connecting" should be interpreted broadly. For example, they can refer to a direct connection or an indirect connection through an intermediate medium; a fixed connection, a detachable connection, or an integrally formed connection; a mechanical connection, an electrical connection, or a connection capable of mutual communication; or the internal connection of two components or the interaction between two components. Those skilled in the art can reasonably determine the specific meaning of the above terms in this invention based on the specific content of the technical solution.

[0049] Reference Figures 1 to 4As shown, a manufacturing process for fitting a hub 300 with a cap is described. The cap 1 includes: a body 11, a transition ring 12 extending axially from one end of the body 11, the transition ring 12 extending radially outward from the end away from the body 11 having radially outwardly protruding corners 13 and positioning bosses 14 alternately distributed in the circumferential direction, the corners 13 having a groove 15 at their radially inner end and a retaining spring 16 engaging through the groove 15, the corners 13 having an outer bevel 13a inclined towards the end away from the body 11 and an inner buckling surface 13b inclined towards the end near the body 11 and extending to the outer bevel 13a, a reinforcing rib 17 being provided between the radially inner end of the transition ring 12 and the body 11, and an avoidance surface 11a being provided on the outer surface of the body 11 near the positioning bosses 14.

[0050] The manufacturing process includes the following steps:

[0051] S1. An initial cap groove 2 is formed in the middle of the hub 300 by casting. The initial cap groove 2 includes an initial profile 21 located on its periphery, and the initial profile 21 includes a cap groove conforming surface 22. The cap groove conforming surface 22 does not require milling, and the casting deformation tolerance of the casting process is ±0.7mm.

[0052] S2, Reference Figure 4 As shown, the initial surface 21 is machined in one step according to the preset processing path 100 to form a cap groove 3. The processed cap groove 3 includes a positioning groove 31 connected to the cap groove conforming surface 22, and a corner guide 32, a cap stop 33, and an inner stop 34 sequentially connected to the positioning groove 31. The corner guide 32 is constricted in the direction close to the cap stop 33, and the inner stop 34 is expanded in the direction away from the cap stop 33. The positioning groove 31 is annular, and the bottom end of the positioning groove 31 is used to axially support the positioning boss 14. The corner 13 is guided sequentially through the corner guide 32 and the cap stop 33 and enters the inner stop 34. The retaining spring 16 provides a force for the corner 13 to resist the inner stop 34, so as to fix it in the cap groove 3.

[0053] To improve aesthetics and maximize the space between the cap groove 3 and the inner side of the cap 1, the depth of the placement groove 31 is greater than the casting deformation tolerance, exceeding 1.5 mm. The bottom of the placement groove 31 has a chamfer to further increase the space between the cap groove 3 and the inner side of the cap 1. (Refer to...) Figure 7a As shown, the gap between the outer surface of the body 11 and the conformal surface 22 of the cap groove has been reduced from the existing 2.1 mm ( Figure 7a The C1 value has been optimized to 1.1mm. Figure 7a(c2). Taking into account machining clamping deviation (0.5mm), machining deviation (±0.1mm), and the 300 coating thickness of the wheel hub (approximately 0.12mm), the clearance is selected within the range of 0.98±0.6mm to ensure appropriate tolerance and achieve the desired appearance and spatial effect. (Refer to...) Figure 7 and Figure 7a As shown.

[0054] By adjusting the gap between the outer side of the body 11 and the conformal surface 22 of the cap groove, the present invention successfully optimized the space between the cap groove 3 and the inner side of the cap 1, thereby reducing the gap between the cap 1 of the wheel hub 300 and the casting by about 45%, and improving the overall aesthetics.

[0055] The corner inlet 32 ​​facilitates the entry of the cap 1 into the cap groove 3. In some embodiments, refer to... Figure 5 and Figure 5a As shown, when the maximum diameter of the retaining angle 13 is less than or equal to the maximum diameter of the positioning boss 14, the retaining angle inlet 32 ​​has an inlet inclined surface 32a and the inlet inclined surface 32a is at an angle of 15-45° with the central axis of the hub 300. The maximum diameter of the retaining angle inlet 32 ​​is greater than the maximum diameter of the retaining angle 13 but less than the diameter of the body 11.

[0056] In other embodiments, refer to Figures 8 to 9b As shown, when the maximum diameter of the retaining angle 13 is greater than the maximum diameter of the positioning boss 14 (e.g., greater than 0.2mm), the retaining angle inlet 32 ​​forms an inwardly concave curve and forms an outer stop 35 with the positioning groove 31. The maximum radius of the retaining angle inlet 32 ​​is greater than the maximum radius of the retaining angle 13 by ≥0.15mm. Figure 9a (b1), the radius of the positioning boss 14 is greater than the radius of the outer stop 35 by ≥0.2mm. Figure 9a (b2), the maximum radius of the locking angle 13 is greater than the radius of the outer stop 35 ≤ 1.2mm ( Figure 9a (b3) The other two cap grooves are the same.

[0057] When the maximum diameter of the retaining angle 13 is greater than the maximum diameter of the positioning boss 14 (e.g., greater than 0.2mm), it is possible to select... Figure 9bThe secondary slotting and assembly process includes: first, aligning the cap 1, whose diameter is larger than that of the positioning boss 14, with the cap groove 3 of the hub 300 on the same axis, so that the outer bevel 13a of the cap 13 fits against the inner stop surface of the hub; then, applying a force of about 4.5 kgf to the outer end of the cap 1, so that the cap 13 passes through the inner stop 34 of the hub, and the cap 1 is pre-slotted for the first time; then, the outer bevel 13a of the cap 1 fits against the guide bevel 32a of the cap 13; then, applying a force of about 4.5 kgf to the outer end of the cap 1 for the second time, so that the cap 13 passes through the cap stop 33 of the hub 300, and the positioning boss 14 of the cap 1 fits against the sinking groove 31 of the hub 300; the retaining spring 16 on the inner side of the cap 13 expands freely, so that the inner buckling surface 13b of the cap 1 circumferentially slotted cap 1 fits against the inner stop 34 of the hub 300, thus completing the secondary slotting assembly.

[0058] Specifically, refer to Figure 4a As shown, the axis of the cap stop 33 is parallel to the central axis of the hub 300, the diameter of the cap stop 33 is 0.3-0.5 mm larger than the diameter of the transition ring 12, and the axial length of the positioning groove diameter 31 is 1.5 mm. Figure 4a (a1), the axial length of the cap stop 33 is 0.5-2.5mm ( Figure 4a Between a2), to reduce the resistance of the cap 1 entering the cap groove 3, the resistance is less than 5 kgf.

[0059] Specifically, refer to Figure 5b As shown, the inner stop 34 includes an inner inclined surface 34a that is inclined to the central axis of the hub 300. The acute angle between the inner inclined surface 34a and the central axis of the hub 300 is less than 43°, and the obtuse angle between the inner inclined surface 34a and the central axis of the hub 300 is 3-25° larger than the obtuse angle between the inner buckle surface 13b of the retaining angle and the central axis of the transition ring 12. The inner inclined surface 34a and the retaining angle 13 are interference fit, and the interference fit amount is 0.2-0.5mm.

[0060] Specifically, refer to Figure 4a As shown, the starting point of the machining path 100 is ≥0.17mm larger on one side than the maximum diameter of the cap 1. Figure 4a (a3) and falls inside the cap groove conforming to the surface 22, so as to achieve the purpose of visual error prevention.

[0061] Specifically, by adjusting the diameter of the cap stop 33 and using a push-pull force gauge to detect the resistance of the cap 1 in the cap groove 3, the pull-off force is ≥5kgf when the diameter of the cap stop 33 is ≤75mm, and ≥8kgf when it is above 75mm, so as to ensure that the cap 1 does not fall off when the vehicle is traveling at high speed or bumpy.

[0062] In some embodiments, refer to Figure 10As shown, during machining, the Far East CNC machine tool WHL-55 was selected, and the cutting tool was an internal hook cutter 200 with a main cutting edge angle of 110° and a 35° rhomboid insert.

[0063] By adopting a one-time machining manufacturing process, there is no need to introduce new milling equipment, which effectively reduces manufacturing costs and makes production more economical and efficient. By simplifying the processing flow and reducing complex steps in the manufacturing process, production efficiency is improved, which helps to complete the manufacturing and fitting of the wheel hub 300 and the cap 1 more quickly. The gap is reduced, which improves the overall appearance.

[0064] Finally, it should be noted that the above specific embodiments are only used to illustrate the technical solutions of the present invention and not to limit it. Although the present invention has been described in detail with reference to examples, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solutions of the present invention without departing from the spirit and scope of the technical solutions of the present invention, and all such modifications or substitutions should be covered within the scope of the claims of the present invention.

Claims

1. A manufacturing process for fitting wheel hubs and caps, characterized in that, The cap (1) includes: a body (11), a transition ring (12) extending axially from one end of the body (11), the transition ring (12) extending radially outward from the end away from the body (11) having a circumferentially alternating corner (13) and a positioning boss (14), the corner (13) having a groove (15) at its radially inner end and a retaining spring (16) being engaged through the groove (15), the corner (13) having an outer bevel (13a) inclined towards the end away from the body (11) and an inner buckle (13b) inclined towards the end near the body (11) and extending to the outer bevel (13a), a reinforcing rib (17) being provided between the radially inner end of the transition ring (12) and the body (11), and an avoidance surface (11a) being provided on the outer side of the body (11) near the positioning boss (14). The manufacturing process includes: An initial cap groove (2) is formed in the middle of the hub (300) by casting. The initial cap groove (2) includes an initial profile (21) located on its periphery, and the initial profile (21) includes a cap groove conforming profile (22). The initial profile (21) is machined in one step according to a preset machining path (100) to form a cap groove (3). The cap groove (3) includes a positioning groove (31) connected to the profile (22) of the cap groove, and a corner guide (32), a cap stop (33), and an inner stop (34) connected in sequence to the positioning groove (31). The corner guide (32) is tapered along the direction close to the cap stop (33), and the inner stop (34) is tapered along the direction far from the cap stop (33). It expands in the direction away from the cap stop (33); wherein, the positioning groove (31) is annular, and the bottom end of the positioning groove (31) is used to axially support the positioning boss (14); the locking angle (13) is guided through the locking angle inlet (32) and the cap stop (33) in sequence and enters the inner stop (34), and the locking angle (13) is fixed in the cap groove (3) by the locking spring (16) against the inner stop (34).

2. The manufacturing process for fitting a wheel hub and a cap according to claim 1, characterized in that, The cap groove conforming surface (22) does not require milling. The casting deformation tolerance of the casting is ±0.7mm. The groove depth of the placement groove (31) is greater than the casting deformation tolerance, which is more than 1.5mm. The bottom of the placement groove (31) has a chamfer to increase the space between the cap groove (3) and the inner side of the cap (1).

3. The manufacturing process for fitting a wheel hub and a cap according to claim 1, characterized in that, When the maximum diameter of the retaining angle (13) is less than or equal to the maximum diameter of the positioning boss (14), the retaining angle inlet (32) has an inlet ramp (32a) and the inlet ramp (32a) is at an angle of 15-45° to the central axis of the hub (300). The maximum diameter of the retaining angle inlet (32) is greater than the maximum diameter of the retaining angle (13) but less than the diameter of the body (11); or, when the maximum diameter of the retaining angle (13) is greater than the maximum diameter of the positioning boss (14), the maximum diameter of the retaining angle (13) is greater than the maximum diameter of the positioning boss (14). When the diameter is used, a secondary groove processing and assembly process is adopted. The corner guide (32) is a concave curve and forms an outer stop (35) with the positioning groove (31). The maximum radius of the corner guide (32) is greater than the maximum radius of the corner (13) by ≥0.15mm. The radius of the positioning boss (14) is greater than the radius of the outer stop (35) by ≥0.2mm. The maximum radius of the corner (13) is greater than the radius of the outer stop (35) by ≤1.2mm.

4. The manufacturing process for fitting a wheel hub and a cap according to claim 1, characterized in that, The axis of the cap stop (33) is parallel to the central axis of the hub (300). The diameter of the cap stop (33) is 0.3-0.5 mm larger than the diameter of the transition ring (12). The axial length of the cap stop (33) is between 0.5-2.5 mm to reduce the resistance of the cap (1) entering the cap groove (3). This resistance is less than 5 kgf.

5. The manufacturing process for fitting a wheel hub and a cap according to claim 1, characterized in that, The inner stop (34) includes an inner inclined surface (34a) that is inclined to the central axis of the hub (300). The acute angle between the inner inclined surface (34a) and the central axis of the hub (300) is less than 43°. The obtuse angle between the inner inclined surface (34a) and the central axis of the hub (300) is 3-25° larger than the obtuse angle between the inner buckle surface (13b) and the central axis of the transition ring (12).

6. A manufacturing process for fitting a wheel hub and a cap according to claim 5, characterized in that, The inner bevel (34a) of the stop and the corner (13) are interference fit, and the interference fit amount is 0.1-0.65mm.

7. The manufacturing process for a wheel hub and cap adapter according to claim 1, characterized in that, The gap between the outer side of the body (11) and the conformal surface (22) of the cap groove is 0.98±0.6mm.

8. The manufacturing process for fitting a wheel hub and a cap according to claim 1, characterized in that, The starting point of the processing path (100) is ≥0.17mm larger than the maximum diameter of the cap (1) on one side and falls inside the conformal surface (22) of the cap groove, so as to achieve the purpose of visual error prevention.

9. A manufacturing process for fitting a wheel hub and a cap according to claim 1, characterized in that, By adjusting the diameter of the cap stop (33) and using a push-pull force gauge, it is ensured that the resistance of the cap (1) in the cap groove (3) is ≥5kgf when the diameter of the cap stop (33) is ≤75mm, and ≥8kgf when it is above 75mm, so as to ensure that the cap (1) does not fall off when the vehicle is traveling at high speed or bumpy.

10. A manufacturing process for fitting a wheel hub and a cap according to claim 1, characterized in that, During machining, an internal hook cutter (200) with a principal cutting edge angle of 110° and a 35° rhomboid insert is selected.

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