Spin Forming Rollers for Variable Wheel Wall Thickness
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Solution Overview
Problem
Existing spin forming methods are limited in their ability to produce a wide variety of shapes efficiently, particularly for vehicle wheels, as they require costly modifications to the spinning mandrel for each change in rim geometry, making high piece numbers economically viable but not flexible for small or individual production.
Innovation Solution
A method and device that allow for independent axial and radial displacement of both inner and outer rollers via a CNC control unit, enabling the creation of a defined wall thickness profile and flexible shaping without modifying the spinning tool, allowing for almost unlimited shape variability and efficient production of workpieces with varying contours.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a fixed spinning mandrel is used to form vehicle wheels, then the manufacturing precision and reliability are improved, but the adaptability to different rim geometries deteriorates, requiring costly mandrel modifications for each design change
Solution Approach 1:
The patent transforms the static spinning mandrel into a dynamic system where the inner contour is defined by a programmable trajectory of the inner roller rather than a fixed physical form. The inner support can be displaced axially and radially independently via CNC control, allowing the same tool to adapt to different rim geometries through software programming rather than physical modification.
Solution Approach 2:
Instead of using a physical negative form (mandrel) for each rim design, the invention uses a digital copy or model of the desired inner contour that guides the motion of the inner roller. The CNC control unit executes pre-programmed trajectories that replicate the desired geometry, eliminating the need for expensive physical mandrel production and modification.
2Device complexity
If inner and outer rollers are mounted on a common roller carrier with fixed distance, then the device complexity is reduced, but the manufacturing precision of wall thickness profile deteriorates, unable to produce variable wall thickness distributions
Solution Approach 1:
The patent segments the roller support system into independent inner and outer support units, each capable of individual displacement control. This segmentation allows the inner support with the inner roller to be positioned independently from the outer support with the outer roller, enabling precise control of the shaping gap to create defined wall thickness profiles with different thicknesses at different locations along the lateral region.
Solution Approach 2:
The invention transforms the static fixed-distance roller arrangement into a dynamic system where both inner and outer roller positions can be independently adjusted via CNC control. This dynamic positioning capability allows the shaping gap to vary along the axial direction, enabling production of wall thickness profiles that range from uniform to highly variable distributions according to design requirements.
3Ease of operation
If spin forming is performed with constant wall thickness or projection spinning, then the ease of operation is improved, but the adaptability to different wall thickness requirements deteriorates
Solution Approach 1:
The patent introduces dynamic, independently controlled displacement of both inner and outer supports via CNC system, transforming the simple constant-thickness or projection spinning process into a sophisticated variable wall thickness forming process. The operator can program different wall thickness profiles by defining the relative motion paths of the inner and outer rollers, maintaining ease of operation through software control while achieving high adaptability.
Solution Approach 2:
The invention enables continuous variation of the wall thickness parameter throughout the forming process by dynamically adjusting the positions of the inner and outer rollers. Instead of being constrained to constant wall thickness or fixed projection angles, the system can program different wall thickness values at different axial locations, allowing optimization of weight and strength characteristics for specific application requirements.
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
Enables the production of workpieces with arbitrary contour and wall thickness profiles, facilitating efficient manufacturing of small or individual pieces without the need for expensive spinning mandrels, and allowing for weight optimization and increased stability of vehicle wheels by adapting wall thickness to loading conditions.
Implementation Method 1
with material thinning, an axially extending lateral region of the workpiece is shaped
Data Source
AI summary
A method and a device for spin forming includes a workpiece set in rotation with a spindle and at least one outer roller is positioned at an outer side of the workpiece. With material thinning, an axially extending lateral region of the workpiece is shaped. At least one inner roller is positioned at an inner side of the workpiece with an inner support, which is displaceable axially and radially relative to the axis of rotation independently of the outer roller. The inner support with the inner roller and an outer support with the outer roller are displaced individually with a CNC control unit, forming at the lateral region a defined wall thickness profile with different wall thicknesses between the at least one outer roller and the at least one inner roller.