Vehicle Wheel Disc Manufacturing with Integrated Window Forming
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Solution Overview
Problem
Existing methods for producing vehicle wheel discs lack sufficient configuration freedom and result in design constraints, fatigue strength, and run-out tolerances issues due to sequential punching operations that do not allow for optimal window formation before finishing the geometrical profile.
Innovation Solution
A method involving multiple material removing operations, including initial window formation and subsequent finish forming, followed by additional window creation, allows for increased design flexibility and improved fatigue strength by altering the window geometry and spoke arrangement, enhancing the wheel's structural integrity and manufacturing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If sequential punching operations are used to create windows after the disc is fully formed, then the manufacturing process is simple, but the design freedom is limited and fatigue strength is reduced
Solution Approach 1:
The patent applies preliminary action by creating window portions during the forming process itself, before the disc is completely formed. The forming tool includes cutting edges that remove material to create window portions while the disc is being formed from the blank, rather than punching windows into a fully formed disc. This allows greater design freedom in window configuration while maintaining manufacturing efficiency.
2Strength
If windows are punched after the disc is fully formed, then the manufacturing steps are fewer, but the fatigue strength and run-out tolerances are compromised
Solution Approach 1:
The patent merges the window creation operation with the disc forming operation. The forming tool integrates both forming surfaces and cutting edges, allowing the disc to be formed and window portions to be created in a single integrated operation. This combination maintains manufacturing efficiency while producing superior fatigue strength because the windows are created when the material is still pliable and can be properly formed without compromising structural integrity.
3Manufacturing precision
If multiple punching operations are used to create windows, then the window configuration is constrained, but the manufacturing process is straightforward
Solution Approach 1:
The patent segments the window creation into multiple window portions that are created during the forming process. Each window is formed as multiple separate portions that are then joined or merged during forming, allowing complex window configurations and spoke arrangements. This segmentation approach enables greater configuration freedom while maintaining manufacturing precision through controlled material removal and forming operations.
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
This approach simplifies the wheel disc production process, improves fatigue strength, and reduces design constraints, resulting in wheels with enhanced performance and accuracy in window formation, particularly in terms of air inlet width and structural rigidity.
Implementation Method 1
subjecting the disc to at least one first punching operation to produce a plurality of first window portions angularly spaced-apart in the disc
Implementation Method 2
subjecting the disc to at least one finish forming operation to finish the geometrical profile of the disc in a windowing area of the disc
Data Source
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Figure 3
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AI summary
Method for producing a disc (3) of a vehicle wheel, comprising the following steps: - providing a partially formed disc, defining a central axis (A-A); - subjecting the disc to a first material removing operation to produce a plurality of first window portions (13a) angularly spaced-apart in the disc; - subjecting the disc to a finish forming operation to finish the geometrical profile of the disc in a windowing area of the disc; and - subjecting the disc to a second material removing operation to produce a plurality of second window portions (13b) angularly spaced-apart at the windowing area of the disc, each of the second window portions cooperating with a respective one of the first window portions to define a corresponding window (13) comprised between a pair of adjacent spokes (3b) and a peripheral portion (11) of the disc.