Wheel Disc Flange Forming via Segmented Drawing and Ironing
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Solution Overview
Problem
Existing manufacturing methods for wheel discs do not effectively maximize the ratio of the minimum length of window portions to the basic length of base portions in the flange portion, which limits the improvement in rigidity and weld strength of the wheel when joined to a wheel rim.
Innovation Solution
A manufacturing method involving the use of molds with specific radii and recessed portions to form the flange portion, where 'drawing' and 'ironing' processes are strategically combined to increase the length of window portions and maintain the base portion's weld strength, thereby enhancing the rigidity and contact area with the wheel rim.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the length of window portions is increased to improve rigidity, then the contact area with wheel rim increases, but the basic length of base portions decreases
Solution Approach 1:
The flange portion is segmented into multiple base portions and window portions arranged circumferentially. This segmentation allows the window portions to provide rigidity through increased contact area with the wheel rim, while the base portions maintain sufficient length for welding by being positioned at strategic locations (including corner regions) where they can preserve adequate basic length despite the presence of extended window portions between them.
2Shape
If drawing process is applied to form flange portion, then the outer edge is bent inwardly, but unbalanced flow phenomenon occurs causing non-uniform thickness
Solution Approach 1:
The manufacturing process applies different local qualities to different regions of the flange portion. Base portions (particularly at corner regions) are formed with controlled material flow to maintain uniform thickness and structural integrity, while window portions between them allow for the natural unbalanced flow phenomenon to occur, resulting in reduced thickness that is acceptable for those non-critical regions. This local differentiation resolves the contradiction by permitting thickness variation only where it does not compromise overall structural integrity.
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 method increases the minimum length of window portions, improving the wheel's rigidity and enhancing the weld strength at the base portion when joined to the wheel rim, while minimizing the 'unbalanced flow phenomenon' to maintain structural integrity.
Implementation Method 1
the outer edge of the disc material is bent inwardly in the vehicle width direction over a whole circumferential region
Implementation Method 2
the inner mold and an outer mold having a cylindrical inner surface with a first inside radius larger than the first outside radius and placed above the inner mold coaxially to the inner mold are brought close relative to each other in the axial direction by one stroke, so that the outer edge of the disc material is bent downward
Implementation Method 3
drawing, and so on several times on a flat disc material
Data Source
AI summary
A manufacturing method for a wheel disc, includes forming a flange portion, wherein the flange portion is formed such that an inner mold and an outer mold having a cylindrical inner surface with a first inside radius larger than the first outside radius and placed above the inner mold coaxially to the inner mold are brought close relative to each other in an axial direction by one stroke so that the outer edge of the disc material is bent downward, and the cylindrical inner surface of the outer mold is provided with recessed portions hollowed outwardly in a wheel radial direction, the recessed portions being formed in ranges corresponding to the window portions in the wheel circumferential direction and in a range from a middle position to a bottom end in the wheel axial direction.