alloy wheel manufacturing
DESCRIPTION
Alloy wheels are wheels that are made from an alloy of aluminium or magnesium. They are typically lighter for the same strength and provide better heat conduction and improved cosmetic appearance over steel wheels.TRANSCRIPT
PRESENTED BY :-NAME :- PANKAJ KUMAR DALAISEMESTER :- 8TH
REGD. NO. :- 1101225142ROLL NO. :- 11-ME/76
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ALLOY WHEEL MANUFACTURING
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CONTENTS Introduction History Components Of Alloy Wheel Reasons For Using Aluminum Properties Required Manufacturing Steps Different Types Of Casting Sheet Metal Process Finishing Operations Critical Analysis Comparison Modern Technologies Conclusion
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INTRODUCTIONAlloy wheels are wheels that are made from an alloy of aluminium or magnesium. They are typically lighter for the same strength and provide better heat conduction and improved cosmetic appearance over steel wheels.
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HISTORY• Invented in 1948.
• First Al wheel – forged.
• Earliest alloy wheels were made of magnesium.
• Used initially because of aesthetic appeal.
• Today 60% wheels are Al wheels.
• Lighter while providing same strength.
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Wheel hub.
Spokes.
Rim.
Components Of Alloy Wheel
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Reasons for using Aluminum
Improved car handling and riding comfort.
Improved grip.
Reduced fuel consumption.
Better braking performance.
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PROPERTIES REQUIRED Stiffness. Yield Strength. Temperature & Corrosion resistance. Fatigue Strength. Impact Resistance. Reduced Weight.
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MANUFACTURING STEPSProcesses used for manufacture of Al wheels.
Casting Forging Sheet Metal Process
Final finishing operations. Painting Varnishing Polishing followed by a clear coating Chrome Wheel Finish
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DIFFERENT TYPES OF CASTING
LOW PRESSURE DIE CASTING
PERMANENT MOLD CASTING
FLOW FORMING (RIM ROLLING)
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Setup for LPDC
LOW PRESSURE DIE CASTING
• Metal stored in crucible.• Air at Pressure(15-100 kPa) introduced.• Molten metal rises into the cavity
between the dies.• The metal solidifies.• The pressure is released after which the
die is opened and casting taken out.
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PERMANENT MOLD CASTING
• Permanent molds made of carbon steels or grey cast iron.
• Molten metal poured into the permanent mold.
• The molds are heated to approximately 500 degrees Fahrenheit.
• Ensures no voids created in the cast.
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FLOW FORMING (RIM ROLLING)
• Begins with LPDC.• Temp. increased to 300-3500C.• Steel rollers push against the rim area
to its final dimension.• Produces light and strong wheels at
reasonable costs.
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FORGINGSingle block of high strength alloy.
Forged into basic wheel shape with 8000 ton press.Strength maximized by heat treatment.
Machined to ensure desired shape.
Drilling of holes and ventilation.Polishing to give a shine.Etching and painting.
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SHEET METAL PROCESS Large strip cut into two round shapes. Ends welded together. Rims shaped by rolling. Nave produced by deep
drawing/stamping. Joining of nave and rims. Surface treatment and coating.
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FINISHING OPERATIONSMachining and finishing to remove
protruding parts and defects during initial processes.
Fine polishing to enhance shine of surface.Chrome wheel finish.Polished clear coat finish.Painting and varnishing.
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CRITICAL ANALYSIS• Difficult step in casting – mold preparation – high complexity of
shapes.• Some properties may get compromised while reducing weight –
wheel blank heated under pressure.• Grains get aligned along one direction during forging – gives
better damage tolerance, increased strength and toughness.• Forged wheels are non – porous and have fine microstructure. Hence they have high fatigue resistance.
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COMPARISONCAST WHEELS
• Low cost of production.• Mediocre fatigue
performance.• Could fail due to sudden
impacts (hitting curbs and potholes).• Can perform with forged
wheels under normal loading conditions.• Small variety of surface
finishes can be applied.
FORGED WHEELS• Relatively expensive.• Better mechanical properties
than cast wheels.• Higher safety due to absence
of pores and cavities.• Can bear higher loads than
cast wheels.• Large variety of surface
finishes can be applied.
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MODERN TECHNOLOGIES• AIR INSIDE TECHNOLOGY
Hollow chambers and spokes.Reduces weight – better driving experience and comfort.Increases load bearing ability by up to 60%.
• CERAMIC POLISHINGVery good surface finish.High strength ceramic particles used.Removes brittleness to a certain extent.
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MODERN TECHNOLOGIES• NANO PAINTWORK
Heat and scratch resistant.Repels dirt, dust, water and other liquids.
• FABRICATIONAssembly of multiple components to produce finished
wheel.Titanium bolts which impart high strength and minimize
failure chances are used.Easy replacement of components.
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CONCLUSION• Alloy wheels are most widely used in the world.• Alloy wheels are better than conventional steel
wheels.•Most widely used processes - casting and forging.• Forged wheels are better than those made by
Casting.Better impact resistance.Fatigue performance.High durability.Lightweight.
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