Abstract:
A method for producing a fabricated vehicle wheel comprising the steps of: (a) providing a rim blank; (b) providing a first tooling fixture for subjecting the rim blank to a preforming operation wherein the cylindrical shape is reshaped to produce a rim preform; (c) providing a second tooling fixture defining a sealed internal chamber and having a tooling member having a predetermined inner surface contour, the sealed internal chamber in fluid communication with a source of high pressurize hydraulic fluid; (d) positioning the rim preform in the internal chamber with an outer surface thereof adjacent the inner surface contour of the tooling member; (e) supplying the high pressure hydraulic fluid to the internal chamber whereby the rim preform is pressed against the adjacent inner surface contour of the tooling member so as to produce a wheel rim having a contour which matches that of the inner surface contour of the tooling member; (f) removing the wheel rim from the second tooling fixture; and (g) securing the wheel rim to a wheel disc to produce the fabricated vehicle wheel.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    This invention relates in general to fabricated vehicle wheels and in particular to an improved fabricated vehicle wheel, wheel rim for use in such a vehicle wheel, and method for producing the same. 
         [0002]    A conventional fabricated bead seat attached vehicle wheel is of a two-piece construction and includes an inner wheel disc and an outer “full” wheel rim. The wheel disc can be cast, forged or fabricated from steel, aluminum, or other alloys, and includes an inner annular wheel mounting portion and an outer annular portion. The wheel mounting portion defines an inboard mounting surface and includes a center pilot or hub hole, and a plurality of lug receiving holes formed therethrough for mounting the wheel to an axle of the vehicle. The wheel rim can be cast, forged or fabricated from steel, aluminum, or other alloys, and includes an inboard tire bead seat retaining flange, an inboard tire bead seat, an axially extending well, an outboard tire bead seat, and an outboard tire bead seat retaining flange. In some instances, a three-piece wheel construction having a mounting cup secured to the wheel disc is used. In both types of constructions, the outer annular portion of the wheel disc is secured to the wheel rim by welding. Typically the wheel disc is secure to the wheel rim in the region of the well of the wheel rim, to thereby produce a well-attached fabricated vehicle wheel or in the region of the outer tire bead seat of the wheel rim, to thereby produce a bead-seat attached fabricated vehicle wheel. 
         [0003]    A full face fabricated wheel is distinguished from other types of fabricated wheels by having a one-piece wheel disc construction. In particular, the full face wheel includes a “full face” disc and a “partial” rim. The full face disc can be formed cast, forged, or fabricated from steel, aluminum, or other alloys. The full face disc includes an inner annular wheel mounting portion and an outer annular portion which defines at least a portion of an outboard tire bead seat retaining flange of the wheel. The wheel mounting portion defines an inboard mounting surface and includes a center pilot or hub hole, and a plurality of lug receiving holes formed therethrough for mounting the wheel to an axle of the vehicle. The partial rim is fabricated from steel, aluminum, or other alloys, and includes an inboard tire bead seat retaining flange, an inboard tire bead seat, an axially extending well, and an outboard tire bead seat. In some instances, the outboard tire bead seat of the rim and the outer annular portion of the disc cooperate to form the outboard tire bead seat retaining flange of the full face wheel. In both types of constructions, the outboard tire bead seat of the rim is positioned adjacent the outer annular portion of the disc and a weld is applied to secure the rim and the disc together. 
         [0004]    A typical sequence of steps which can be used to produce a wheel rim for a fabricated vehicle wheel is disclosed in U.S. Pat. No. 4,185,370 to Evans. As shown in this patent, the method includes the steps of: (a) providing a flat sheet of suitable material, such as aluminum or steel; (b) forming the sheet into a cylindrical hoop or band; (c) flaring the lateral edges of the hoop radially outwardly to produce a rim preform having flanges suitable for positioning on a roll forming machine; (d) subjecting the rim preform to a series of roll forming operations to produce a wheel rim having a predetermined shape; and (e) expanding the wheel rim to a produce a finished wheel rim having a predetermined circumference. 
         [0005]    U.S. Pat. No. 4,962,587 to Ashley, Jr. et al. discloses another method for producing a wheel rim. According to the method of this patent, a preformed wheel rim is provided having opposed finished tire bead seat retaining flanges, opposed finished tire bead seat surfaces, a well, and an axially extending inboard leg. Next, the well and adjacent rim end are mounted on a mandrel and end plate, respectively, for rotation therewith. A flow spinning roller is then actuated and advanced to engage the well and inboard leg portion thereby thinning-stretching the well and leg portions of the preformed wheel rim. 
         [0006]    Other methods for producing wheel rims by rolling or pressing operations are disclosed in U.S. Pat. No. 3,347,302 to Lemmerz, U.S. Pat. No. 4,127,022 to Bosch, and U.S. Pat. No. 4,143,533 to Bosch. 
       SUMMARY OF THE INVENTION 
       [0007]    This invention relates to an improved fabricated vehicle wheel, wheel rim for use in such a vehicle wheel, and method for producing the same. According to one embodiment, a method for producing a fabricated vehicle wheel comprising the steps of: (a) providing a wheel rim blank formed from a suitable material, the wheel rim blank being in the shape of a generally cylindrical hoop; (b) providing a first tooling fixture for subjecting the wheel rim blank to a preforming operation wherein the cylindrical shape is reshaped to include a plurality of differently shaped portions and produce a wheel rim preform; (c) providing a second tooling fixture defining a sealed internal chamber and having a tooling member having a predetermined inner surface contour, the sealed internal chamber in fluid communication with a source of high pressurize hydraulic fluid; (d) positioning the wheel rim preform in the sealed internal chamber of the second tooling fixture with an outer surface of the wheel rim preform adjacent the predetermined inner surface contour of the tooling member; (e) supplying the high pressure hydraulic fluid to the sealed internal chamber of the second tooling fixture whereby the wheel rim preform is pressed against the adjacent inner surface contour of the tooling member so as to produce a finished wheel rim having a contour which matches that of the predetermined inner surface contour of the tooling member; (f) removing the finished wheel rim from the second tooling fixture; and (g) securing the finished wheel rim to a wheel disc to produce the fabricated vehicle wheel. Also, this invention relates to a fabricated vehicle wheel produced according to the method described immediately above. 
         [0008]    In another embodiment of the invention, a method for producing a fabricated wheel rim adapted for use in a fabricated vehicle wheel comprising the steps of: (a) providing a wheel rim blank formed from a suitable material, the wheel rim blank being in the shape of a generally cylindrical hoop; (b) providing a first tooling fixture for subjecting the wheel rim blank to a preforming operation wherein the cylindrical shape is reshaped to include a plurality of differently shaped portions and produce a wheel rim preform; (c) providing a second tooling fixture defining a sealed internal chamber and having a tooling member having a predetermined inner surface contour, the sealed internal chamber in fluid communication with a source of high pressurize hydraulic fluid; (d) positioning the wheel rim preform in the sealed internal chamber of the second tooling fixture with an outer surface of the wheel rim preform adjacent the predetermined inner surface contour of the tooling member; (e) supplying the high pressure hydraulic fluid to the sealed internal chamber of the second tooling fixture whereby the wheel rim preform is pressed against the adjacent inner surface contour of the tooling member so as to produce a finished wheel rim having a contour which matches that of the predetermined inner surface contour of the tooling member; and (f) removing the finished wheel rim from the second tooling fixture for subsequent securing to a wheel disc to produce the fabricated vehicle wheel. Also, this invention relates to a fabricated wheel rim produced according to the method described immediately above. 
         [0009]    In yet another embodiment of the invention, a method for producing a fabricated vehicle wheel comprising the steps of: (a) providing a wheel rim blank formed from a suitable material selected formed from the group consisting of steel, aluminum, alloys thereof, magnesium, or titanium, the wheel rim blank being in the shape of a generally cylindrical hoop; (b) providing a first tooling fixture for subjecting the wheel rim blank to a preforming operation wherein the cylindrical shape is reshaped to include a plurality of differently shaped portions and produce a wheel rim preform, the wheel rim preform including at least a pair of opposed angled end portions; (c) providing a second tooling fixture defining a sealed internal chamber and having a tooling member having a predetermined inner surface contour, the sealed internal chamber in fluid communication with a source of high pressurize hydraulic fluid; (d) positioning the wheel rim preform in the sealed internal chamber of the second tooling fixture with an outer surface of the wheel rim preform adjacent the predetermined inner surface contour of the tooling member and with the second tooling fixture capturing the opposed angled end portions of the wheel rim preform; (e) supplying the high pressure hydraulic fluid to the sealed internal chamber of the second tooling fixture whereby the wheel rim preform is pressed against the adjacent inner surface contour of the tooling member so as to produce a wheel rim having a contour which matches that of the predetermined inner surface contour of the tooling member; (f) removing the wheel rim from the second tooling fixture; and (g) securing the wheel rim to a wheel disc to produce the fabricated vehicle wheel. Also, this invention relates to a fabricated vehicle wheel produced according to the method described immediately above. 
         [0010]    Other advantages of this invention will become apparent to those skilled in the art from the following detailed description of the preferred embodiments, when read in light of the accompanying drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0011]      FIG. 1  is a block diagram illustrating a sequence of steps for producing an first embodiment of a fabricated vehicle wheel in accordance with the present invention. 
           [0012]      FIG. 2  is a view of a portion of a first tooling for use in producing a first embodiment of a wheel rim, showing the forming of a wheel rim preform according to the method of the present invention. 
           [0013]      FIG. 3  is a view of a portion of a second tooling for use in producing the first embodiment of a finished wheel rim, showing the initial position of the wheel rim preform before the second tooling is actuated. 
           [0014]      FIG. 4  is another view of the second tooling, showing the actuated state of the second tooling in order to produce the first embodiment of the finished wheel rim. 
           [0015]      FIG. 5  is a view of the first embodiment of the fabricated vehicle wheel, including the first embodiment of the finished wheel rim of  FIG. 4 . 
           [0016]      FIG. 6  is a view of a second embodiment of a fabricated vehicle wheel, including the first embodiment of the finished wheel rim of  FIG. 4 . 
           [0017]      FIG. 7  is a view similar to  FIG. 4  showing a portion of a second tooling for use in producing a second embodiment of a finished wheel rim, showing the end working position of the second tooling to produce the second embodiment of the finished wheel rim. 
           [0018]      FIG. 8  is a view of a third embodiment of a fabricated vehicle wheel, including the second embodiment of the finished wheel rim of  FIG. 7 . 
       
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0019]    Referring now to  FIG. 1 . there is illustrated a block diagram illustrating a sequence of steps for producing a first embodiment of a fabricated vehicle wheel, indicated generally at  80  in  FIG. 5 , in accordance with the present invention. The fabricated wheel disc  80  of this embodiment is illustrated as being adapted for use in producing a fabricated “bead seat” vehicle wheel. Although the present invention is illustrated and described in conjunction with the particular vehicle wheel constructions disclosed herein, it will be appreciated that the invention can be used in conjunction with other types of fabricated vehicle wheel constructions, if so desired. For example, as shown herein or with modifications thereto, the present invention may be used in connection with other types of fabricated vehicle wheels, such as for example in a “full face” type of vehicle wheel, such as shown in FIG. 5A of U.S. Pat. No. 5,533,261 to Kemmerer, in a “well attached” type of vehicle wheel, such as shown for example in FIG. 3 of U.S. Pat. No. 5,188,429 to Heck et al., a “bimetal” type of vehicle wheel construction including an aluminum disc and a steel rim, such as shown for example in U.S. Pat. No. 5,421,642 to Wei et al., and a “modular wheel” type of construction, such as shown for example in U.S. Pat. No. 5,360,261 to Archibald et al., the disclosures of each of these patents incorporated by reference in entirety herein. 
         [0020]    Initially, as shown in  FIG. 1 , in step  10 , a wheel rim blank, indicated at  18  in  FIG. 2  is provided. The wheel rim blank  18  can be formed from any suitable material, such as for example, steel, aluminum, alloys thereof, magnesium, or titanium. Preferably, the wheel rim blank  18  is formed from steel. The wheel rim blank  18  is generally in the shape of a substantially cylindrical hoop. 
         [0021]    Next, in step  12 , a tooling fixture or apparatus, indicated generally at  20  in  FIG. 2  in accordance with this invention, is provided to be used to produce a wheel rim preform, indicated generally at  22  in phantom in  FIG. 2 , from the wheel rim blank  18 . The tooling fixture  20  defines an axis X and includes a first tooling member  24 , a second tooling member  26 , and a third tooling member  34 . The first tooling member  26  can be a one-piece tooling member or can be made up of two or more tooling members. In the illustrated embodiment, the first tooling member  26  is a generally annular one-piece tooling member and includes an outer end, indicated generally at  30 , having a predetermined outer surface contour. In the illustrated embodiment, the predetermined outer surface contour of the outer end  30  includes a generally annular first surface  30 A, a generally angled or inwardly tapered second surface  30 B, and a generally annular third or end surface  30 C. Alternatively, the profile and/or construction of the outer end  30  of the first tooling member  26  can be other than illustrated if so desired. 
         [0022]    In the illustrated embodiment, the second tooling member  28  is a generally annular one-piece tooling member and includes an outer end, indicated generally at  32 , having a predetermined outer surface contour. In the illustrated embodiment, the predetermined outer surface contour of the outer end  32  includes a generally annular first surface  32 A, a generally angled or inwardly tapered second surface  32 B, and a generally angled or inwardly tapered third surface  32 C, and a generally annular fourth or end surface  32 D. Alternatively, the profile and/or construction of the outer end  32  of the second tooling member  28  can be other than illustrated if so desired. 
         [0023]    In the illustrated embodiment, the third tooling member  34  can be a one-piece tooling member or can be made up of two or more tooling members. In the illustrated embodiment, the third tooling member  34  is a one-piece tooling member and is preferably moveable in the direction of arrows C 1  and C 2  as it is rotated relative to the first and second tooling members  26  and  28  will be discussed below. As can be seen in  FIG. 2 , in the illustrated embodiment the third tooling member  34  is a roll spinning roller and is provided with a curved or rounded outer end  34 A. Alternatively, the profile and/or construction of the outer end  34 A of the third tooling member  34  can be other than illustrated if so desired. 
         [0024]    During step  12 , the first tooling member  26  is moved in the direction of arrow B and the second tooling member  28  is moved in the direction of arrow A to predetermined positions relative to one another and the wheel rim preform  18 . In the illustrated embodiment, the position to which the first tooling member  26  and the second tooling member  28  are moved is noted by line C. In other words, the first tooling member  26  is moved to the right in  FIG. 1  and the second tooling member  28  is moved to the left in  FIG. 1  until their ends abut one another at the line C. 
         [0025]    Next, in step  12 , the third tooling member  34  is moved in the direction of arrow C 1  so that the outer end  34 A thereof engages the wheel rim blank  18 . Following this, the third tooling member  34  is moved in the direction of arrow C 2  so that the outer end  34 A thereof is operative to reshape the wheel rim blank  18  against the associated outer surfaces  30 B- 30 C and  32 B- 32 D of the first and second tooling members  26  and  28 , respectively, to produce a wheel rim preform  22  having a desired shape. 
         [0026]    As can be seen in  FIG. 2 , the shape or profile of the wheel rim preform  22  generally corresponds to the shape of the associated outer surfaces  30 B- 30 C and  32 B- 32 D of the first and second tooling members  26  and  28 , respectively, which are used. Thus, in the illustrated embodiment, the wheel rim preform  22  includes a generally angled first or outer end portion  22 A, a generally annular second portion  22 B, a generally angled third portion  22 C, and a generally angled fourth or inner end portion  22 D. Preferably, the wheel rim preform  22  is formed in one step during step  12 ; however, depending upon the final shape of the wheel rim preform  22  which is desired and/or the material of the wheel rim blank  18  which is selected, the forming of the wheel rim preform  22  during step  12  can be done in more than one step if so desired. Alternatively, the metal forming process which is used to produce the wheel rim preform  22  and/or the shape thereof formed during step  12  can be other than illustrated if so desired. 
         [0027]    Next, in step  14 , a tooling fixture or apparatus, indicated generally at  40  in  FIGS. 3 and 4 , is provided to produce a finished wheel rim, indicated generally at  52  in  FIG. 4 , having a desired final shape from the wheel rim preform  22 . As shown therein, the tooling fixture  40  includes a first tooling member  42 , a second tooling member  44 , a third tooling member  46 , and a fourth tooling apparatus  48 . 
         [0028]    The first tooling member  42  can be a one-piece tooling or “press” member or can be made up of two or more tooling members. In the illustrated embodiment, the first tooling member  42  is a generally annular one-piece tooling member and includes an outer end, indicated generally at  42 A, having a annular recess  42 B formed therein which defines an annular shoulder  42 C therein. Similarly, the second tooling member  44  can be a one-piece tooling or “press” member or can be made up of two or more tooling members. In the illustrated embodiment, the second tooling member  44  is a generally annular one-piece tooling member and includes an outer end, indicated generally at  44 A, having an annular recess  44 B formed therein which defines an annular shoulder  44 C therein. Alternatively, the profile and/or construction of the first tooling member  42  and/or the second tooling member  44  can be other than illustrated if so desired. 
         [0029]    In the illustrated embodiment, the third tooling member  46  is a generally annular split or two-piece tooling or “die” member and includes an inner surface, indicated generally at  46 A, having a predetermined inner surface contour. As can be readily appreciated, in the illustrated embodiment, the predetermined inner surface contour of the third tooling member  46  preferably generally corresponds to the shape of the finished wheel rim  52 . 
         [0030]    The fourth tooling apparatus  48  includes a source of hydraulic fluid  50 , a pump  52 , a motor  54  operatively coupled to the pump  52 , a first fluid line  56  connecting the fluid source  50  to the pump  52 , and a second fluid line  58  connecting the pump  52  to an interior cavity or sealed chamber  60  of the tooling fixture  40 . As shown in the illustrated embodiment, the tooling fixture  40  preferably includes at least a pair of seals  62  to provide the sealed chamber  60 . 
         [0031]    In step  14 , the wheel rim preform  22  is positioned within the tooling fixture  40  and the tooling members  42 ,  44  and  46  are moved thereagainst to the position as shown in  FIG. 3 . As shown therein, in this position, opposed ends  22 E and  22 F of the wheel rim preform  22  are disposed adjacent the shoulders  42 C and  44 C so as to effectively capture or position the wheel rim preform  22  in the tooling fixture  40 . Next, the motor  54  is actuated so that the pump  52  is operative to supply, preferably high pressure hydraulic fluid, into the sealed chamber  60  such that the wheel rim preform  22  is pressed against the adjacent inner surface contour  46 A of the third tooling member  46  so that the shape or contour of the finished wheel rim  64  matches that of the inner surface contour  46 A of the third tooling member  46 A. Preferably, the inner pressure applied to the wheel rim preform  22  during step  14  is about 2000 bar. However, depending upon the material and/or thickness of the wheel rim preform  22  which is used, the inner pressure which is applied during step  14  can be other than described if so desired. 
         [0032]    In the illustrated embodiment, the finished wheel rim  64  includes an inboard tire bead seat retaining flange  66 , an inboard tire bead seat  68 , a well  70 , an outboard tire bead seat  72 , and an outboard tire bead seat retaining flange  74 . 
         [0033]    Following this the finished wheel rim  64  is removed from the tooling fixture  40  and is secured to a wheel disc, indicated generally at  76  in  FIG. 5  by one or more welds  78 , to produce the finished fabricated bead seat attached vehicle wheel  80 . Preferably, following step  14 , the wheel rim  64  is ready for securing to the wheel disc  76 ; however, in some instances, slight machining or trimming of the wheel rim  64  may needed prior to assembly to the wheel disc  76 . 
         [0034]    As discussed above, the present invention can be used to produce a wheel rim for use in other kinds of fabricated vehicle wheels. For example, referring to  FIG. 6 , there is illustrated a fabricated well attached vehicle wheel, indicated generally at  90 . In this embodiment, the vehicle wheel  90  can include a wheel rim  92 , which can be formed in a manner similar to that for wheel rim  64 . The wheel rim  92  can then be secured to a preformed wheel disc  94  by one or more welds  96  to produce the well attached vehicle wheel  90 . 
         [0035]    Referring now to  FIG. 7  and using like reference numbers to indicate corresponding parts, there is illustrated a tooling fixture or apparatus, indicated generally at  100 , which is used to produce a finished wheel rim, indicated generally at  102  therein. The tooling fixture  100  is the same as the tooling fixture  40  shown in  FIGS. 3 and 4 , except that in this embodiment a third tooling member  46 ′ includes an inner surface, indicated generally at  46 A′, having a predetermined inner surface contour which is different from the inner surface contour  46 A of third tooling member  46  shown in  FIGS. 3 and 4 . Also, in this embodiment, adjacent surfaces of the third tooling member  46 ′ and a first tooling member  42 ′ are shaped or configured so as to produce an inturned flange  102 A during step  14 . As a result of this, in this embodiment the finished wheel rim  102  is a partial wheel rim which is adapted to be secured to a full face wheel disc by one or more welds  106 , as shown in  FIG. 8 , to produce a fabricated full face fabricated vehicle wheel  108 . 
         [0036]    One advantage of the present invention is that the number of steps used to produce the wheel rim  64 ,  92 ,  102  for use in producing the respective vehicle wheel,  80 ,  90 ,  108 , is reduced compared to conventional “mechanical” wheel rim forming processes, which typically include at least three mechanical metal forming operations to produce a finished wheel rim. As discussed above, after the wheel rim is preformed, the final shape of the wheel rim can be produced in a single operation using high pressure hydraulic fluid. Also, the present invention can more accurately form the finished wheel rim  64 ,  92 ,  102  to more precise and/or complex shapes all in a single forming operation using the high pressure hydraulic fluid. 
         [0037]    In accordance with the provisions of the patent statutes, the principle and mode of operation of this invention have been described and illustrated in its various embodiments. However, it must be understood that the invention may be practiced otherwise than as specifically explained and illustrated without departing from the scope or spirit of the attached claims.