3D-Printed Wheel Rim Cavities for Axial Impact Resistance
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Solution Overview
Problem
Current vehicle wheel rims, particularly those made of aluminum, face challenges in reducing weight while maintaining mechanical integrity and resistance to axial impacts, especially when using three-dimensional metal printing methods.
Innovation Solution
The design incorporates a vehicle wheel rim printed with a metal alloy using three-dimensional printing, featuring a substantially circular barrel with cavities and reinforcing walls to reduce weight while ensuring axial impact resistance, including a front hook cavity, bead seat cavity, and hump cavities separated by thick walls to form a V-shaped or triangular partition around the bead seat, occupying between 40% to 80% of the front fittings part volume.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If cavities are introduced in the rim to reduce weight, then the weight decreases, but the mechanical strength and impact resistance deteriorate
Solution Approach 1:
The rim is segmented into multiple cavities (front hook cavity, front bead seat cavity, front hump cavity, rear hook cavity, rear bead seat cavity) separated by reinforcing walls. This segmentation allows weight reduction through cavity introduction while the separating walls maintain structural integrity and impact resistance by distributing stresses throughout the rim structure.
Solution Approach 2:
Different regions of the rim have different cavity configurations tailored to their specific functional requirements. The front fittings part contains multiple cavities (front hook cavity, front bead seat cavity, front hump cavity) while the rear fittings part has different cavity arrangements. This local differentiation optimizes weight reduction in each region while maintaining the specific mechanical properties required for axial impact resistance in critical areas.
2Weight of moving object
If composite materials like kevlar or carbon are used to reduce weight, then the weight decreases, but the reliability and durability worsen due to fragility
Solution Approach 1:
The invention changes the material parameter from fragile composite materials (kevlar, carbon) to ductile metal alloy, which can deform plastically under impact loads. This parameter change maintains weight reduction benefits while significantly improving reliability and resistance to longitudinal and lateral impacts, as metal can absorb impact energy through deformation rather than fracturing like composite materials.
3Weight of moving object
If three-dimensional metal printing is used to create cavities in the front face, then the front face weight decreases, but the overall rim weight reduction is limited
Solution Approach 1:
The invention extends cavity formation from the traditional two-dimensional front face into the third dimension by creating cavities within the barrel thickness. The front hook cavity, front bead seat cavity, and rear hook cavity penetrate through or into the barrel, utilizing the radial and axial dimensions to remove material and reduce weight throughout the entire rim structure, not just at the front face.
Data Source
AI summary
A vehicle wheel rim is printed with a metal alloy by a three-dimensional printing method. The rim includes a substantially circular rolling strip defined by a front edge and a rear edge. The rolling strip includes a central rim base, a front part including fittings for a front tire support, located between the rim base and the front edge, and a rear part including fittings for a rear tire support, located between the rim base and the rear edge. The rim is designed to be mounted on a vehicle such that the front edge is located on an outer side of the vehicle and the rear edge is located on an inner side of the vehicle. The rolling strip includes a plurality of cavities in the thickness thereof and in a radial section.