Vehicle Wheel Ribs With Additive Reinforcement for Fatigue Resistance
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Solution Overview
Problem
The stamping process for producing vehicle wheels limits the achievable performance features due to the need for constant sheet metal thickness, restricting fatigue resistance and stiffness without compromising weight.
Innovation Solution
A vehicle wheel with a rim and disc of sheet metal, where metal additive material is deposited in layers to create localized steep thickness changes, allowing for reinforcement in specific regions without increasing overall thickness, achieved through additive manufacturing techniques like three-dimensional printing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the sheet metal thickness is increased throughout the component to improve fatigue resistance and stiffness, then the mechanical performance is improved, but the weight increases
Solution Approach 1:
The patent applies local quality by creating localized thickness variations through additive material formations (ribs) only in specific regions of the wheel disc and rim where reinforcement is needed. This allows the wheel to have increased strength and fatigue resistance at critical locations while maintaining the original constant thickness in non-critical areas, thereby avoiding unnecessary weight increase throughout the entire component.
Solution Approach 2:
The patent transitions from a two-dimensional constant thickness sheet metal component to a three-dimensional structure with variable thickness by adding material formations that protrude from the surface. This dimensional change enables localized reinforcement without requiring uniform thickness increase, resolving the contradiction between strength improvement and weight control.
2Ease of manufacture
If the sheet metal thickness is kept constant to maintain manufacturing simplicity, then the ease of manufacture is maintained, but the fatigue resistance and stiffness are limited
Solution Approach 1:
The manufacturing process is segmented into two distinct stages: first, the base wheel components are manufactured using traditional stamping processes with constant thickness; second, additive material formations are applied selectively to specific regions. This segmentation allows the benefits of simple stamping manufacturing to be retained while adding the capability for localized reinforcement to improve fatigue resistance and stiffness.
Solution Approach 2:
The patent creates a composite structure by combining the base sheet metal component with additive material formations. This composite approach allows the wheel to benefit from both the manufacturing simplicity of stamping processes and the enhanced mechanical properties provided by the added material, resolving the contradiction between ease of manufacture and strength.
3Strength
If localized formations are created on the disc and rim to improve performance, then the fatigue resistance is improved, but the manufacturing complexity increases
Solution Approach 1:
The manufacturing process is divided into two independent stages: conventional stamping for the base components and separate additive formation application. This segmentation reduces manufacturing complexity by allowing each stage to be optimized independently, avoiding the need for complex integrated processes while still achieving localized reinforcement for improved fatigue resistance.
Solution Approach 2:
The base wheel components are manufactured in advance using well-established stamping processes before the additive material formations are applied. This preliminary action allows the use of simple, proven manufacturing techniques for the bulk material, while the complex localized formations are added subsequently, reducing overall manufacturing complexity.
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 enhances fatigue resistance and stiffness while maintaining weight efficiency by providing targeted reinforcement, overcoming the limitations of traditional stamping processes.
Implementation Method 1
at least one formation of metal additive material deposited in a plurality of layers is formed on at least one of said rim and disc
Data Source
Figure 1~2
Figure 3
Figure 4~5
AI summary
Wheel (1) for vehicles, comprising a rim (2) of sheet metal, comprising on its axially outer side an outer flange (27), an outer bead seat (26) and a retaining hump (25), as well as a rim well (24) connected to the outer bead seat (26) through the retaining hump (25), and a disc (3) of sheet metal, comprising a cover part (31) and a connection part (32) protruding axially from the cover part (31), wherein the connection part (32) of the disc (3) is fixed to a radially inner surface of the rim (2), wherein at least one formation (41, 42) of additive material is formed on the rim and/or disc, the formation defining a steep thickness change with respect to a surrounding region of sheet metal.