Single-Piece Vehicle Wheel Forming Without Reverse Rolling

Instead of using reverse rolling to form the flange portion, the patent applies forward rolling techniques where the metal band is progressively formed into the flange shape through controlled rolling operations. This inverts the conventional approach by eliminating the complex reverse rolling step while achieving the same geometric outcome through simpler forward deformation processes.

The patent divides the wheel manufacturing process into distinct sequential stages: forming the wheel disc from the metal band, then separately forming the hub portion through controlled deformation. This segmentation allows each portion to be formed independently through simple processes without requiring complex splitting operations, reducing both material stress and production cost.

The patent optimizes the metal blank thickness parameter to maintain sufficient material strength throughout the forming process. By carefully selecting and controlling the thickness parameter, the process achieves the required flange and hub shapes through progressive deformation without exceeding material stress limits, avoiding the need for excessive thinning that would increase stress concentrations.

The patent merges the manufacturing of the wheel disc, rim, and hub portions into a single integrated process using one continuous metal band. This combining of previously separate components into one monolithic structure eliminates the need for welding operations, thereby removing stress concentration at weld joints and simplifying the overall manufacturing process.