Vehicle Wheel Disk Weight Reduction via Local Thickness Segmentation
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Solution Overview
Problem
Conventional manufacturing methods for vehicle wheel disks fail to adequately lighten the disk while maintaining sufficient strength and rigidity, as they primarily reduce thickness in the disk flange without effectively addressing the entire structure.
Innovation Solution
The method involves forming a vehicle wheel disk from a flat plate material with specific thickness-reduced portions at the radially outer hat portion and disk flange, including a thick disk flange portion at the inner end, to achieve weight reduction and improved rigidity, and a manufacturing process that includes ironing and diameter-changing steps to achieve these configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If only the disk flange is reduced in thickness by ironing, then the manufacturing process is simple, but the weight reduction is insufficient
Solution Approach 1:
The disk is divided into multiple regions with different thickness characteristics: the disk flange is thinned by ironing while the hat portion maintains original thickness, creating segmented thickness zones that optimize both weight reduction and structural functionality
Solution Approach 2:
Different portions of the disk are given different thickness properties according to their functional requirements - the disk flange is reduced in thickness for weight reduction while the hat portion retains full thickness for strength, achieving local optimization of material distribution
2Weight of moving object
If the disk flange is reduced in thickness, then weight is reduced, but the strength and rigidity may be compromised
Solution Approach 1:
The disk structure is designed with non-uniform thickness distribution where the disk flange is thinned for weight reduction while the hat portion maintains original thickness to preserve strength and rigidity in critical load-bearing areas
Solution Approach 2:
The disk is segmented into different thickness zones - the thinned disk flange region and the full-thickness hat region - allowing weight reduction in non-critical areas while maintaining structural integrity in load-bearing regions
3Weight of moving object
If the disk flange is reduced in thickness uniformly, then weight is reduced, but the assembly accuracy with rim deteriorates
Solution Approach 1:
The thickness reduction is applied locally to specific portions of the disk flange rather than uniformly across the entire flange, preserving dimensional accuracy and assembly fit in critical areas while achieving weight reduction in less critical regions
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 effectively lightens the vehicle wheel disk while maintaining strength and improving assembly accuracy with the rim, allowing for a higher lightening rate and enhanced rigidity, ensuring the disk's structural integrity.
Implementation Method 1
a first step for ironing a portion or an entirety of a disk material portion from M1 to M2 to a cylindrical portion having a thickness smaller than a thickness of the disk material portion before ironing
Data Source
AI summary
A vehicle wheel disk and a manufacturing method thereof is provided. The vehicle wheel disk is manufactured from a disk material of a flat plate. The vehicle wheel disk includes a hub coupling portion, a disk flange and a hat. The hat includes a hat top protruding outwardly in an axial direction of the disk, a radially inner hat portion connecting the hat top and the hub coupling portion, and a radially outer hat portion connecting the hat top and the disk flange. In the vehicle wheel disk, a first thickness-reduced portion is smaller in thickness than the disk material that is formed at the radially outer hat portion.