Flow-Formed Vehicle Wheel Structure Without Disc-Rim Gaps
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Solution Overview
Problem
Existing steel-framed vehicle wheels have gaps between the wheel disc and rim, which impair aerodynamics and require excessive material usage, leading to increased weight and material waste.
Innovation Solution
A one-piece vehicle wheel design with a bowl segment and rim segment formed from a metallic material, featuring a transition element that eliminates the need for a circumferential weld, providing a continuous contour and reducing material overlap, achieved through flow forming processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If wheel disc and rim are joined with circumferential weld in traditional two-piece design, then structural strength is achieved, but aerodynamic performance deteriorates due to gaps between parts
Solution Approach 1:
The patent merges the wheel disc and rim into a single one-piece formed body, eliminating the gap between parts that causes aerodynamic drag. The continuous contour from wheel mounting surface to outer rim flange removes the need for circumferential welds while maintaining structural integrity through flow forming processes.
Solution Approach 2:
While creating a one-piece body, the patent segments the formed body into functional zones: wheel mounting surface, transition element, and outer rim flange. This segmentation allows optimization of each zone's geometry for both strength and aerodynamics without requiring separate components.
2Ease of manufacture
If traditional two-piece wheel design with circumferential weld is used, then manufacturing simplicity is maintained, but material usage increases leading to higher weight
Solution Approach 1:
The wheel disc and rim are combined into a single formed body created through flow forming processes, eliminating the need for circumferential welds and reducing material overlap. This merging reduces overall material usage and wheel weight while maintaining manufacturing feasibility through specialized forming techniques.
Solution Approach 2:
The patent changes the manufacturing approach from traditional welding of separate parts to flow forming processes that shape metal into a one-piece body. This parameter change in the manufacturing process enables material optimization and weight reduction while achieving the desired wheel geometry.
3Reliability
If wheel disc and rim are joined with circumferential weld, then structural integrity is achieved, but manufacturing energy consumption increases
Solution Approach 1:
The one-piece formed body eliminates the need for circumferential welds, removing the energy-intensive welding process from manufacturing. The continuous metal structure formed through flow forming provides structural integrity without requiring additional joining operations.
Solution Approach 2:
The patent extracts the welding operation from the manufacturing process by creating a one-piece formed body. This removal of the welding step significantly reduces manufacturing energy consumption while maintaining structural integrity through the continuous metal structure.
4Ease of operation
If traditional wheel design with gap between wheel disc and rim is used, then ease of assembly is maintained, but aerodynamic drag increases requiring wheel covers
Solution Approach 1:
The wheel disc and rim are merged into a one-piece formed body with a continuous contour, eliminating the gap that causes aerodynamic drag. This design achieves smooth airflow around the wheel without requiring separate wheel covers, while the integrated structure maintains ease of assembly as a single unit.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The design enhances aerodynamics, reduces material usage and weight, and minimizes manufacturing energy consumption while maintaining technical characteristics like handling and safety, with potential for various vehicle types.
Implementation Method 1
the one-piece shape of the vehicle wheel is not forged, but rather formed or manufactured by means of flow forming
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
The invention relates to a vehicle wheel (1) comprising a bowl segment (2) and a rim segment (3), wherein the bowl segment (2) comprises a wheel mounting surface (10) for connecting the vehicle wheel (1) to a vehicle hub and a transition element (11), wherein the transition element (11) is arranged between the wheel mounting surface (10) and the outer rim flange (12), wherein the rim segment (3) comprises an outer (12) and an inner rim flange (13) as well as a rim well (16) arranged between the two flanges (12, 13), wherein the segments (2, 3) of the vehicle wheel (1) are formed in one piece from a metallic material, in particular from a bandage, in particular formed, to create a one-piece, continuous vehicle wheel contour.