Method and device for casting vehicle wheels

Abstract: A method for casting a vehicle wheel using a casting device is disclosed, in which the has a mold provided with a main body (M), a casting space (4) and a gate (43). The main body (M) of the mold includes a casting space section (453) for forming the rim of the wheel, and the gate (43) is arranged at one side of said casting space section (453) and opens into said casting space section. During casting and cooling the wheel, the disk portion of the wheel is partially and separately forcefully cooled. A vehicle wheel casted with this method has miniaturized structure. As only the hub portion is forcefully cooled, the necessary tensile strength of the bolt hole in the hub portion can easily be obtained at low cost.

Description: (Field of the invention) This invention relates to a method and a device for casting a wheel having a rim and a disk portion for vehicles having a mold provided with a main body, a casting space and a gate. (Brief description of the prior art) In a conventional casting device, when a casting is going to be manufactured, a mold temperature is set sufficiently high in order to obtain a favourable run of a hot melt. This conventional casting device, however, has the disadvantage that on account of the high temperature it takes long time for hardening the melt. As a consequence the casting structure of the product does not become dense and therefore it is difficult to obtain a high strength. Further, in a known low pressure casting device for manufacturing vehicle wheels (Japanese Patent Early Laid-open Publication No. Scho 55-120465), a main body of the mold is provided with a gate at its lower part and the hot melt is poured into a casting space through the gate. The cooling device is located at a lower part of the main body of the mold. This makes it difficult to maintain the hot melt at a constant level of temperature, so that casting defects tend to occur. Notwithstanding that a high strength is required for the disk portion of a vehicle wheel, it is difficult to cool the disk portion with this conventional casting device, since the gate is disposed at the lower part of the main body of the mold. Therefore, it is difficult to improve the strength of the disk portion. The present invention has been accomplished in order to overcome the above-mentioned disadvantages of the prior art. Summary of the invention It is therefore the object of the present invention to provide a method and a casting device for casting a vehicle wheel, in which no casting defect can be found, the casting structure is fine and the disk portion of the wheel has improved strength. This object of the invention is achieved by a method in which the disk portion of the wheel is partially and separately forcefully cooled when the vehicle wheel is casted and cooled. The object can further be achieved by a casting device for producing a vehicle wheel having a vehicle wheel like molding space formed in a main body of a mold, the mold further being provided with a casting space and a gate, wherein the main body of the mold has a first casting space section for forming the rim of the wheel and the gate is arranged at one side of said first casting space section and opens into said first casting space section. The first casting space section might be connected through a connecting portion with a second casting space section for forming a spoke portion of the wheel, wherein the gate opens into said connecting portion. According to another embodiment of the invention the first casting space section for casting the rim of the wheel is provided at one side with a plurality of gates which are opened into said first casting space section. The mold may comprise a first mold for forming the outer side or surface of a design, for instance for forming the disk of the wheel, a second mold or nest for forming the reverse side or surface of the design or disk and a third mold for forming the outer periphery of the rim of the wheel. The third mold can be provided with a passage for the hot melt, which opens at one end into the first casting space section for forming the rim and at the other end at an outer peripheral surface of the third mold. Means are provided for changing a hot melt flow passage communicated with an opening of the outer peripheral surface of the third mold. A hot melt inlet port of said hot melt flow passage being opened up underneath. The means for changing the hot melt flow passage may be movable in a way to interlock or to connect the passage to the second mold for forming the reverse side of the disk. The mold may include a plurality of main bodies with cooling means arranged in the vicinity of a third casting space section for forming the disk of the wheel. In this case the gate is opened into the first casting space section and is connected with the interior of a hot melt reserving furnace, from which the hot melt is forcefeeded into the mold through the gate. The plurality of main bodies may have open first casting space sections for forming the rim, wherein the gates of the adjacent main bodies are communicated with each other, the in this way communicated gates might be connected with the interior of the furnace for the hot melt reserve. Further cooling means may be provided in the vicinity of the gate in the main body. The main body is preferably provided with primary cooling means generally uniformly arranged thereon, wherein the portion in said main body for forming the disk comprises a nest being provided with auxiliary cooling means which are separated from said primary cooling means. The auxiliary cooling means may be disposed under a prescribed portion of a bottle hole of the vehicle wheel to be casted. According to another embodiment of the invention a preselected number of annular casting members and a single disc-shaped casting member are provided in order to define a space for forming a feeding head. Said required number of annular casting members can be stacked up one upon the other, the disc-shaped member being placed on the upper surface of the annular casting member arranged at the upper end. Further is provided a cavity communicated with the space for forming the feeding head. The feeding head has the property to excellently retain the heat. With the method according to the invention it is possible to obtain wheels with the appropriate tensile strength that is, wheels with varying tensile strength over the wheel. Optimal dendrite arm spacing or dendrite secondary arm space (DAS II) can be obtained in casted wheel made of aluminum alloy. The DAS II, which is a measured value obtained by microscopic observations of the formation of a cast-metal block or a casting, is a value characterizing the tensile strength of the product and is dependent on the cooling rate and/or the proceeding condition of solidification of the casting. The object of the invention is therefore further achieved by a wheel made of an aluminium alloy having dendrite structure and characterized in that the value of the dendrite secondary arm spacing DAS II of the alloy at a tip portion of the rim most remote from the disk portion of the wheel is smaller than the DAS II value at the rim body portion, the DAS II value at the central portion of said disk and the DAS II value at the rim carrying portion of said disk portion being equal to or smaller than the DAS II at the body portion. This wheel is characterized by high safety. The invention will become apparent to those skilled in the art after consideration of the following preferred embodiments of the invention which are provided by way of examples without limiting the invention. Brief description of the Drawings. Fig. 1 is a sectional view of a first embodiment, Fig. 2 shows a detail from fig. 1, Figs. 3 to 7 show each an embodiment of casting devices, Fig. 8 is an enlarged sectional view of a portion indicated by VIII of fig. 7, Fig. 9 is a bottom view of a disk-shaped molding member of fig. 8, Fig. 10 is a bottom view of an annular molding member of fig.8, Fig. 11 is a sectional view of a mold for casting a wheel cup, Fig. 12 is a perspective view of a wheel cup casted with the mold of fig. 11, Fig. 13 shows a sectional view of another embodiment, Fig. 14 is a view of the part indicated by the arrow II in fig. 13, Fig. 15 is an enlarged view of the portion indicated at III in fig. 13, Fig. 16 is a sectional view taken on line IV-IV of fig. 14, Fig. 17 is a sectional view taken on line V-V of fig. 14, Fig. 18 is a schematic view of a secondary arm growing at each side of a main shaft of a dendrite in an aluminium alloy, Fig. 19 shows an explanatory view of the distance between a plurality of secondary arm and Fig. 20 shows a partly omitted sectional view obtained by cutting a wheel of a vehicle along a plane including a rotational shaft of a wheel. In fig.1 is shown a main body M of a mold for molding a vehicle wheel. The main body M of the mold enclosing a casting space 4 comprises a combination of a lower mold 1, horizontal molds 2 and an upper mold 3. The lower mold 1 is supported by a supporting device 114. The casting space 4 has a configuration of a vehicle wheel and comprises a first casting space section 451 for casting the disk of the wheel, a second casting space section 452 for forming the spoke and a third casting space section 453 for casting the rim of the wheel. 11 denotes a first nest of the lower mold 1. The first nest 11 forms the outer surface of the disk of the wheel. A second nest 31 of the upper mold 3 forms the rear surface of the disk of the wheel. In the lower mold 1 is formed a primary cooling hole 611 and in the first nest 11 is formed an auxiliary cooling hole 612. By flowing a cooling fluid as cooling water within the cooling holes 611 and 612 the lower mold 1 and the first nest 11 are cooled. A hot melt passage 42 is formed in the horizontal mold 2 extending through a gate 43 to the third casting space section 453. The hot melt flowing through the hot melt passage 42 is fed into the casting space 4 through the gate 43. A feeding space 41 for feeding the head space is connected with the hot melt passage. A reserve of hot melt is contained in a furnace 91 on which is mounted a pipe 73 for feeding hot melt into the passage 42. For this the upper end of the pipe 73 is communicating with the passage 42 of the horizontal mold 2. Accordingly, if pressure air is flowing through an air hole 911 of the furnace 91 to pressurise the surface D of the hot melt in the furnace 91, the hot melt is pressed through the pipe 73 and the hot melt passage 42 into the casting space 4. The furnace is provided with a bellows 93 arranged between the furnace 91 and the pipe 73 and with a heater 94 for maintaining the hot melt at a constant temperature. As can be seen in Fig.2, the gate 43 may be opened into the connecting portion between the second casting space section 452 and the third casting space section 453 for forming the spoke and the rim respectively. On account of the fact that the cooling means are arranged at the lower portion of the casting space 4 the hot melt passes far from the cooling means, so that the temperature of the hot melt can be easily maintained at a constant value. Further, as a large space is available at the lower part of the main body of the mold, the disk portion can be cooled sufficiently. Accordingly, if such a casting device is used, wheels will be obtained having a fine casting structure and disk portions with improved strength and without showing defects. The embodiment shown in fig.3 is similar to the device of fig.1. The difference consists in that the embodiment of fig.3 has a plurality of pipes 73 for feeding hot melt and a plurality of hot melt passages 42 and gates 43. Each pipe 73 is communicated through a hot melt passage 42 and a gate 43 with the third casting space section 453. With this embodiment the productivity can be improved by shortening the time for pouring the hot melt. Fig.4 shows a mold in which the lower mold 1 is formed to design the outer surface or side of the product whereas the upper mold 3 designs the rear side. The horizontal mold 2 is for forming the outer side of the rim. An auxiliary means 7 for changing the hot melt flow is provided having one end in communication with a hot melt port 222 and the other end in communication with a hot melt inlet port 223 opened underneath. The hot melt inlet port 223 is connected with the pipe 73 through a flat plate-shaped filter 74. The auxiliary means 7 is mounted in such a way that the means 7 can be interlocked with the nest 31 (mold for forming the rear side of the disk) and the upper mold 3 (mold for forming the rear side of the design). Accordingly the casting device for a vehicle wheel described above exhibits the following technical effects. On account of the available large space in the vicinity of the disk portion, the disk portion can be cooled sufficiently. Consequently the structure of the casted disk portion of the wheel is miniaturized and the strength thereof can be improved. As the auxiliary means for changing the hot melt passage, which is communicated with the hot melt port, is disposed on the outer peripheral surface of the rim, for example, it is possible to remove only the thin plate-shaped hot melt passage portion from the first mold without bending or separating the thin plate-shaped hot melt passage portion. Fig.5 shows a mold having a plurality of main bodies M, which are connected to only one furnace 91 for the hot melt reserve. Accordingly, with this mold casting productivity can be improved and heat losses of the hot melt reserve in the furnace can be minimized. Fig.6 shows a another mold having a plurality of main bodies M connected to the one furnace 91. In this case adjacent gates 43 of adjacent main bodies M are communicated with each other. Accordingly, in this mold for casting a vehicle wheel, heat losses of the hot melt can be minimized, and the casting device can be miniaturized. According to fig.7 the casting device comprises a mold M having a lower mold 1, an intermediate mold 11, a horizontal mold 2, an upper mold 3 and an upper auxiliary mold 333. The mold M encloses a casting space 4 having a shape of a vehicle wheel. A nest 111 projects from the intermediate mold 11 and extends to the inside of the casting space 4. The nest 111 is adapted to form a shaft hole of the wheel. The hot melt passage 42 extends sideward in the horizontal mold 2 and opens at one end through a gate 43 into a side portion for forming the rim of the casting space 4. The other end of the hot melt passage 42 opens into an outer surface of the horizontal mold 2. 7 denotes a second auxiliary mold arranged on the outer side of the horizontal mold 2. A dome-shaped primary space 71 is formed inside of the second auxiliary mold 7 and is opened at the bottom. Further a connecting passage 72 is formed in the second auxiliary space 7 for connecting the primary space 71 with the entrance 222 of the hot melt passage 42. The outer side opening 521 of the connecting passage 72 at an outer side of the second auxiliary mold 7 is opposite to the opening or entrance 222 of the hot melt passage 42 at the outer side of the horizontal mold 2. Accordingly, a hot melt within the primary space 71 can pass through the connecting passage 72 into the hot melt passage 42. 731 denotes a stroke auxiliary ring which is abutted against a peripheral edge portion of a lower opening 711. At the bottom of the stroke auxiliary ring 731 is arranged a stroke main body 732. The stroke main body 732 and the stroke auxiliary ring 731 together form the so-called "stroke". A flat plateshaped filter 74 is held between the auxiliary mold 7 and the stroke auxiliary ring 731. This filter 74 shows a net-like configuration and is adapted to filtrate the hot melt which is to be fed to the auxiliary mold 7 as a hot melt changing device. Fig. 8 shows a detail VIII around the nest 111. An inserting hole 314 is formed in an upper surface of a central portion in the upper mold 3. The inserting hole 314 is communicated with the casting space 4. Annular molding members 81, 82 and 83 are inserted into the inserting hole 314 through a space S and are then gradually stacked up one upon the other. In this embodiment, the inner diameter of the middle stage annular molding member 82 is smaller than the inner diameter of the lower stage annular molding member 81. Similarly, the inner diameter of the upper stage annular molding member 83 is smaller than the inner diameter of the middle stage annular molding member 82. The inner peripheral surface of the annular molding members 81, 82 and 83 are tapered and dilated toward the lower end thereof. Connecting portions on the inner surface of each of the annular molding members 81, 82 and 83 show a step-like configuration. This arrangement is made in order to prevent an occurrence of an undercut even when the annular molding members 81, 82 and 83 are moved in the horizontal direction within the inserting hole 314 on account of the space S. 84 denotes a disc-shaped molding member which is inserted into the inserting hole 314 through the space S in the same manner as the annular molding member 81, 82 and 83. This disc-shaped molding member 84 is placed on the upper surface of the upper annular molding member 83. The inner peripheral portion of the annular molding members 81, 82, 83 and the lower surface of the disc-shaped molding member 84 form a space A for forming a feeding head. A connecting portion between the disc-shaped molding member 84 and the annular molding member 83 is also formed with a step portion in order not to generate an undercut as mentioned. The disc-shaped molding member 84 is provided with degasing holes 841 and vents B. 842, 831, 821 and 811 denote degasing grooves which are formed at each lower surfaces of the annular molding members 81, 82 and 83 (see also Figs. 9 and 10. Fig. 9 shows the disk-shaped molding member 84 and Fig. 10 shows the annular molding member 83). These grooves 842, 831, 821 and 811, when stacked up, function as a degasing portion (see Fig.8). In a casting device as mentioned above, heat becomes difficult to be conducted at the molding portion which forms the space for forming the feeding head. Accordingly, in the case that this molding device is used, there can be obtained an excellent heat insulation of the feeding head. Furthermore, according to the molding device of this invention, the space between the contact surfaces of the annular molding members and the space between the contact surfaces of the annular molding member and disc-shaped molding member can be utilized as degasing means when a hot melt is poured. The annular molding member and disc-shaped molding member can be moved independently, and they can be arranged in a form so that a film of the hot melt can easily be destroyed by vibrations. Fig.11 shows a main mold M for molding a wheel cap C (Fig. 12) which comprises a combination of a lower mold 1 and an upper mold 3. This main mold M has a wheel cap-shaped molding space 4. A hot melt port 422 and a hot melt passage 42 are formed in the upper mold 3 on a border surface between the upper mold 3 and the lower mold 1. The hot melt passage 42 connects the hot melt port 422 with the casting space 4. A mark means 412 for casting a mark on the cap C is formed on an upper wall surface of the casting space 4. This casting mark means 412 is designed with the mark ABC and is printed on the surface of the cap C (Fig.12). According to the mold shown in Fig.13 the nest 11 of the lower mold 1 is secured to the central part of the lower mold 1 by a bolt 12. This first nest 11 forms the outer surface of the disk portion of the vehicle wheel. Similarly, 111 denotes a second nest of the lower mold 1 which is secured to the outer surface of the first nest 11 also by the bolt 12. This second nest 111 forms an axle hole of the vehicle wheel. Also, 31 denotes a third nest of the upper mold 3. In the central part of the upper mold 3 is inserted a third nest 31. The nest 31 forms a rear surface of the disk portion. The hot melt passage 42 is formed in the horizontal mold 2. This hot melt passage 42 is continuous to the third casting space section 453 through the weir 43. The hot melt, which passed the hot melt passage 42, is fed into the casting space 4 through the weir 43. In Figs. 14 and 17 are shown straight holes 613 formed in the lower mold 1. These straight holes 613 are blocked at the end portions with blind plugs 615 and are annularly communicated with each other to form a primary cooling flow passage, corresponding to a primary cooling means 611. 617 denote connecting holes formed in the lower mold 1 in the vertical direction. Each of these connecting holes 617 is communicated with the end portion of the primary cooling flow passage 611. Cooling water may be fed through the connecting holes 617 into the primary cooling flow passage 611 to forcefully cool the lower mold 1 and thus the main body M of the mold. In Figs. 14 to 16 are shown auxiliary straight holes 614 formed in the first nest 11. These auxiliary straight holes 614 are blocked at the end portions thereof with blind plugs 616 and are annularly communicated with each other to form a first auxiliary cooling flow passage corresponding to an auxiliary cooling means 612. 618 denote connecting holes formed in the first nest 11 in the vertical direction. Each of these connecting holes 618 is communicated with the end portion of the first auxiliary cooling flow passage 612. Through these connecting holes 618 cooling water may be fed into the first auxiliary cooling flow passage 612 to forcefully cool the first nest 11 and thus the main body M of the mold. In Figs. 14,15 and 17 is shown a vertical hole 813 formed between the connecting holes 617 of the primary cooling flow passage 611 in the lower mold 1. This vertical hole 813 is disposed in the vicinity of the weir 43 and is provided with a cooling device 815 secured thereto by screw means. This cooling device 815 has a nozzle 816 and jets a cooling fluid such as, for example, a cooling water into the vertical hole 813 through the nozzle 816. 817 denotes a water discharging port of the cooling device 815. Similarly, 814 denotes a horizontal hole which is formed in the vicinity of the weir 43 at the side surface of the lower mold 1. This horizontal hole 814 is blocked at its opening end with a blind plug 818 and communicated at its end portion with the vertical hole 813. The vertical hole 813, the horizontal hole 814, and the cooling device 815 form the second auxiliary cooling flow passage 812. If cooling water is fed through the vertical hole 813, an area in the vicinity of the weir 43 of the lower mold 1 can be cooled concentrately. With the casting device for casting vehicle wheels as mentioned above, it is possible to cool the hot melt within the third casting space section 451 for the rim which is in the vicinity of the weir more effectively than the hot melt elsewhere. Accordingly, if such a mold of a vehicle wheel is used, even when a weir is formed in the third casting space section the hot melt forming these portions can generally simultaneously be hardened with a hot melt forming other portion. As a result, the structure of a vehicle wheel, which is to be cast, becomes uniform and thus, the rigidity thereof becomes uniform. With a method for casting a vehicle wheel as mentioned above a vehicle wheel with miniaturized structure can be obtained. As only the hub portion is forcefully cooled, the strength of a bolt hole in the hub portion can easily be obtained at low cost. On account of the auxiliary cooling means, the cooling effect will difficultly be conducted to other mold portions. Consequently the casting of the vehicle wheel can easily be practised. When the auxiliary cooling means, is disposed at a lower part of a bolt hole predetermined portion of the vehicle wheel, the predetermined portion of the bold hole can partly be cooled. Fig.18 shows the dendrite secondary arms of a casted aluminum alloy. The spacing between the dendrite secondary arms DAS II is used as indication of a size in a micro-structure of such an alloy. The dendrite in an aluminum alloy, as schematically shown in Fig.18, has a secondary arm L growing at each side of a main shaft K. For measuring the spacing of the dendrites a distance (N) between the secondary arms L can be measured. In some cases, the size DCS of the cell of the secondary arm is measured. The measurement of the DAS II as shown in Fig.19 is obtained by means of a secondary branch method, in which a plurality of values are obtained by dividing a distance between a plurality of secondary arms with the number of the secondary arms included in the distance and the obtained plurality of values are expressed in an average value. Fig.20 shows a sectional view of the wheel of a vehicle obtained by cutting the wheel P by a plane including the rotational shaft of the wheel. A rim barrel portion (P6) and a rim carrying portion (P3) of a disk portion are strongly acted by a deflection moment during rotation of the wheel. Therefore, this portion is required for a casting to be high in strength. It is generally understood that the strength of a casting is high, if the crystal of the dendrite is minute. Accordingly, a casting with a small measured value of the DAS II is high in strength. Therefore, the DAS II measured at the rim barrel portion (P6) and the rim carrying portion (P3) in the disk portion are preferably small. The jointing portion (P5) between the rim portion and the disk portion necessarily become large in thickness in view of casting, so that cooling of the hot melt is delayed. As a result, the crystal of the dendrite becomes somewhat coarse. However, the crystal is preferably small as much as possible. The following is a summary of preferable conditions in view of behaviour of such wheel. 1) The measured value of the DAS II of the rim end portion P4 opposite the side of the disk of the wheel is smaller than the measured value of the DAS II of the rim barrel portion P6. 2) The measured value of the DAS II of the rim carrying portion P3 of the disk portion is smaller than the measured value of the DAS II at the central portion P1 of the disk. 3) The measured value of the DAS II at the rim carrying portion P3 of the disk portion is equal to or smaller than the measured value of the DAS II at the rim barrel portion P6. A casted wheel which satisfies the above conditions is preferred. A vehicle wheel having such value is high in tensile strength at its required portions. The values of the DAS II measured in the vehicle wheel are shown in Table 1. Sample No. 1-1a-1 is the measured value of the DAS II at the central portion P1 of the disk of the wheel and is the measured value of the first one corresponding to a portion of the weir front according to the casting plane. Sample No. 1-1a-2 is the measured value of the DAS II at an intermediate portion P2 of the disk of the wheel and is the measured value of the first one corresponding to a portion of the weir front according to the casting plane. Sample No. 1-1a-3 is the measured value of the DAS II at the rim carrying portion P3 of the disk portion of the wheel and is the measured value of the first one corresponding to the front weir according to the casting plane. Sample No. 1-1a-4 is the measured value of the DAS II at the rim end portion P4 of the disk side of the rim portion of the wheel and is the measured value of the first one corresponding to a portion of the weir front according to the casting plane. Sample No. 1-1a-5 is the measured value of the DAS II at the jointed portion P5 between the disk portion and the rim portion of the wheel and is the measured value of the first one corresponding to a portion of the weir front according to the casting plane. Sample No. 1-1a-6 is the measured value of the DAS II of the rim barrel portion P6 of the wheel and is the measured value of the first one corresponding to a portion of the weir front according to the casting plane. Sample No. 1-1a-7 is the measured value of the DAS II of a portion P7 of an intermediate position between the rim barrel portion P6 and the rim end portion P8 opposite the disk side at the rim portion of the wheel and is the measured value of the first one corresponding to a portion of the weir front according to the casting plane. Sample No. 1-1a-8 is the measured value of the DAS II of the rim end portion P8 opposite the disk side of the wheel and is the measured value of the second one corresponding to a portion of the weir front according to the casting plane. In the same manner, the sample number "1" in the first position represents a sample of the vehicle wheel of the present invention, the sample number "1" in the middle position represents one corresponding to a portion of the weir front according to the casting plane and likewise "2" represents one corresponding to a portion rotated at 90° from the weir front according to the casting plane, and the sample number "1" in the last position represents one of the central portion P1 of the disk, likewise "2" represents one of the middle portion P2 of the disk, "3" represents the rim carrying portion P3 of the disk portion of the wheel, "4" represents the rim end portion P4 of the rim portion nearest from the disk portion, "5" represents the jointed portion P5 between the disk portion and the rim portion, "7" represents the rim barrel portion P6, "7" represents the portion of the intermediate position between the rim barrel portion P6 and the rim end portion, and "8" represents the rim end portion P8 of the opposite disk side, and the characters "a" and "b" in the middle position represent the first and second samples respectively collected from the same position of a plurality of vehicle wheels of the present invention. Also, the number "2" in the first position represents the conventional vehicle wheel according to a low pressure casting method as a comparison example and similarly. "3" represents the conventional vehicle wheel according to a gravity casting method as a comparison example. The results of the shock test and the rotary bending test of the sample picked up from a group of vehicle wheels which has such measured values were excellent compared with those of the comparison examples of the conventional vehicle wheels. Accordingly, a vehicle wheel of the present invention not only satisfies the safety standard but also ensures uniformity with high performance. As described in the foregoing, according to the present invention, there can be provided a vehicle wheel in which there can be estimated a performance behaviour for each part which was unable to make clear by a macrotest observation as a whole wheel such as a shock test or a rotary bending test of a wheel. Therefore, the present invention greatly contributes to the development of industry. Sample No measured DAS II values sample No. measured DAS II values sample No. measured DAS II values 1-1a-8 26 µm 1-1b-8 24 µm 1-2a-8 26 µm 1-1a-7 29 µm 1-1b-7 30 µm 1-2a-7 29 µm 1-1a-8 34 µm 1-1b-6 32 µm 1-2a-6 29 µm 1-1a-5 36 µm 1-1b-5 30 µm 1-2a-5 30 µm 1-1a-4 26 µm 1-1b-4 25 µm 1-2a-4 24 µm 1-1a-3 26 µm 1-1b-3 25 µm 1-2a-3 29 µm 1-1a-2 33 µm 1-1b-2 33 µm 1-2a-2 35 µm 1-1a-1 38 µm 1-1b-1 33 µm 1-2a-1 35 µm 1-2b-8 25 µm 2-1-8 23 µm 3-1-8 46 µm 1-2b-7 27 µm 2-1-7 28 µm 3-1-7 42 µm 1-2b-6 29 µm 2-1-6 29 µm 3-1-6 33 µm 1-2b-5 29 µm 2-1-5 35 µm 3-1-5 30 µm 1-2b-4 22 µm 2-1-4 22 µm 3-1-4 20 µm 1-2b-3 27 µm 2-1-3 37 µm 3-1-3 30 µm 1-2b-2 30 µm 2-1-2 40 µm 3-1-2 30 µm 1-2b-1 31 µm 2-1-1 40 µm 3-1-1 35 µm

Claims: Method for casting a vehicle wheel having a rim and a disk portion, using a casting device for producing a vehicle wheel, having a mold provided with a main body (M), a casting space (4) and a gate (43), characterized in that the main body (M) of the mold including a casting space section (453) for forming the rim of the wheel, and the gate (43) being arranged at one side of said casting space section (453) and opening into said casting space section, wherein during casting and cooling the wheel, the disk portion of the wheel is partially and separately forcefully cooled. Casting device for producing a vehicle wheel, having a rim and a disk portion, the casting device having a mold provided with a main body (M), a casting space (4) and a gate (43), characterized in that the main body (M) of the mold including a casting space section (453) for forming the rim of the wheel, and the gate (43) being arranged at one side of said casting space section (453) and opening into said casting space section, the device being constructed to partially and seperately forcefully cooling the disk portion of the wheel during casting and cooling the wheel. Device according to claim 2, wherein said casting space section (453) is provided at one side with a plurality of gates (43) opening into said casting space section and the casting space (4) of the main body (M) including a second casting space section (452) for forming a spoke portion of the wheel, said second casting space section (452) being connected with the first casting space section (453) for forming the rim through a connecting portion, the gate (43) being opened up at the connecting portion. Device according to one of the claims 2 to 3, wherein comprising a first mold (1) for forming the outer side of a design, a second mold (3) for forming the reverse side of the design and a third mold (2) for forming an outer periphery of the rim, the third mold (2) including a hot melt passage (42), one end of the hot melt passage being opened into the first casting space section (453) and the other end being opened at an outer peripheral surface of the third mold (2), the hot melt passage (42) being opened underneath through a hot melt inlet port (223), further including means (7) for changing the hot melt passage (42) communicated with an opening (222) at the outer peripheral surface of the third mold (2), the changing means (7) being movable for interlocking said hot melt passage of the second mold (3) for forming the reverse side of the design. Device according to claim 2, wherein the mold including a plurality of main bodies (M), the gate (43) of each main body (M) being opened into respective first casting space section (453) and being connected with the interior of a furnace (91) for a hot melt reserve, from which the hot melt is forced feeded into the mold through the gates (43), and the mold including a furnace (91) for a hot melt reserve opened into the first casting space section (453) for forming the rim, the gates (43) of the adjacent main bodies (M) being communicated with each other and being connected with the interior of the furnace (91). Device according to one of the claims 2 to 5, wherein including cooling means (611,612) disposed in the vicinity of the gate (43) in the main body (M). Device according to one of the claims 2 to 5, wherein including cooling means (611,612) disposed in the vicinity of the third casting space section (451) for forming the disk of the wheel. Device according to one of the claims 2 to 5, wherein the main body (M) is provided with primary cooling means (611) generally uniformly arranged thereon, said casting space section (453) for forming the rim comprising a nest (11), said nest being provided with auxiliary cooling means (612) separately from said primary cooling means (611) and wherein the auxiliary cooling means (612) being disposed under a prescribed portion of a hole of the vehicle wheel which is to be casted, said hole having the form of a bottle. Device according to claim 2, wherein including a preselected number of annular molding members (81,82,83) and a single disc-shaped molding member (84) in order to define a casting space (A) for forming a feeding head, said annular molding members being stacked up one upon the other, the disc-shaped molding member (84) being placed on the upper surface of the annular molding member (83) arranged at the upper end, further, the casting space (4) communicating with the casting space (A) for forming the feeding head. Vehicle wheel made of aluminum alloy by a method according to claim 1 and whith a device according to claim 2, wherein the wheel having dendrite structure and including a disk portion (P1,P2, P3) and a rim portion (P4,P5,P6, P7,P8), characterized in that the spacing between dendrite secondary arms (DAS II) of the alloy at a tip portion (P8) of the rim most remote from the disk portion of the wheel (P) being smaller than the DAS II at the rim barrel portion (P6), the DAS II at a rim carrying portion (P3) of said disk portion is smaller than the DAS II at the central portion (P1) of said disk portion, and the DAS II at the rim carrying portion (P3) of said disk portion being equal to or smaller than the DAS II at the rim barrel portion (P6).

Inventors: KATO TAKASHI, KUREBAYASHI MASARU, TOTSUKA HAISAO, URUMA MASAAKI, YAMAMOTO MASAMI, KATO, TAKASHI, KUREBAYASHI, MASARU, TOTSUKA, HAISAO, URUMA, MASAAKI, YAMAMOTO, MASAMI
Applicants: ASAHI TEC CORP, ASAHI TEC CORPORATION
Application year: 1989
Main classification: B22C9
IPC codes: B22C9, B22D15