Patent Publication Number: US-11027324-B2

Title: Single piece vehicle wheel manufacturing process

Description:
FIELD OF INVENTION 
     The embodiment herein generally relates to the field of manufacturing vehicle wheel out of a single piece. More specifically, the embodiment provides a novel method for manufacturing a vehicle wheel using single metal band. Further, the method provides a vehicle wheel manufacturing process with simple steps without the need for reverse rolling and splitting of work piece. 
     BACKGROUND AND PRIOR ART 
     In general, for manufacturing a wheel for a vehicle different methods are followed. The wheels can be made by assembling a multi piece wheel or the wheels can be manufactured using a single piece. In multi piece wheel manufacturing process, a central disc of the wheel and a wheel rim are formed separately. Further the central disc and wheel rim have to be assembled accordingly and welded together as a final wheel for a vehicle. In case of a single piece wheel manufacturing process, the whole wheel is formed using a single blank that can be a cylindrical, circular or rectangular metal sheet. 
     Some facts need to be considered, while assembling and welding final multi piece wheel for a vehicle. The rim must be machined appropriately to prevent damage to the tire, due to the presence of sharp edges in the rim portion. Further, the rim should be air tight to maintain the air pressure in between the tire and rim. In order to avoid such contemplation, manufacturers prefer single piece wheels manufacturing. 
     Generally, in the single piece wheel manufacturing process, the requirement for raw material is less when compared to multi piece wheel. The fabrication process is also simple. Further, the single piece wheel manufacturing process eliminates stress concentration due to the welding process as welding is not required in the single wheel manufacturing process as opposed to a multi piece wheel. In addition to that the production cost is also lesser in a single wheel process when compared to the multi piece wheel manufacturing process. 
     Vehicle wheels fabricated from a single piece of metal are already known in the prior art. In the existing prior arts, the single piece wheel manufacturing process requires reverse rolling to form a flange portion. Further in another prior art, the process requires splitting the metal portion for forming the hub portion. In some cases, to form the flange and hub portion the metal blank thickness is reduced and then accordingly deformed to the required shape. 
     Therefore, there is a need to develop a single piece wheels manufacturing process with simple steps without the need for reverse rolling. Further, there is a need for a novel method to manufacture a wheel using single band without the need for splitting process. Furthermore, there is a need for a novel method to manufacture a vehicle wheel without subjecting the work piece to more stress and tension. 
     Objects of the Invention 
     Some of the objects of the present disclosure are described herein below: 
     A main object of the present invention is to provide a novel method for manufacturing a vehicle wheel using single metal band as a work piece. 
     Another object of the present invention is to provide a novel method for manufacturing a vehicle wheel with simple fabrication techniques. 
     Still another object of the present invention is to provide a novel method for manufacturing a vehicle wheel without the need for reverse rolling for obtaining a flange portion. 
     Yet another object of the present invention is to provide a novel method for manufacturing a vehicle wheel component without the need for splitting the work piece. 
     Another object of the present invention is to provide a novel method for manufacturing a vehicle wheel at low cost. 
     The other objects and advantages of the present invention will be apparent from the following description when read in conjunction with the accompanying drawings, which are incorporated for illustration of preferred embodiments of the present invention and are not intended to limit the scope thereof. 
     SUMMARY OF THE INVENTION 
     In view of the foregoing, an embodiment herein provides a novel method for manufacturing a vehicle wheel using single metal band as a work piece. The method for manufacturing a vehicle wheel with a single work piece comprising the steps of, placing a metal band in a mandrel provided at a machining tool; forming the metal band/work piece for making a desired length of rim and a wheel disc; wherein size of the rim and the wheel disc can be formed according to the requirement; spinning a nave portion of the work piece for shaping the wheel disc; wherein the nave spinning of the work piece can be utilized to fix an inner width of the wheel; spinning the work piece for making a disc flange and a gutter portion of the wheel; rolling one end of the rim portion of the work piece that is connected to the wheel disc portion, to form the required gutter portion of predetermined shape and thickness; spinning the rim portion of the work piece further to form a tire seat and well area; forming a flange flare by bending another end of the rim portion; forming the flange portion of the wheel rim by bending the flange flare to desired shape; machining flange edge, nave and bore to avoid sharp edges; reaming of bolt holes and chamfering bores at the wheel disk portion of the wheel. 
     According to an embodiment, before performing the spinning process for forming the gutter and disc flange portion of the wheel, boltholes and a central bore is formed. Further, after forming the flange portion at another end of the rim portion, air hole for the wheel disc is pierced and coining the air hole is also performed. The machining process is performed for obtaining final desired shape of the wheel. 
     These and other aspects of the embodiments herein will be better appreciated and understood when considered in conjunction with the following description and the accompanying drawings. It should be understood, however, that the following descriptions, while indicating preferred embodiments and numerous specific details thereof, are given by way of illustration and not of limitation. Many changes and modifications may be made within the scope of the embodiments herein without departing from the spirit thereof, and the embodiments herein include all such modifications. 
    
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
       The detailed description is set forth with reference to the accompanying figures. In the figures, the left-most digit(s) of a reference number identifies the figure in which the reference number first appears. The use of the same reference numbers in different figures indicates similar or identical items. 
         FIG. 1  illustrates sectional view of metal band fixed onto a machining tool, according to an embodiment herein; 
         FIG. 2  illustrates sectional view of first spin forming process, according to an embodiment herein; 
         FIG. 3  illustrates sectional view of final spin forming process, according to an embodiment herein; 
         FIG. 4  illustrates sectional view of nave spinning process, according to an embodiment herein; 
         FIG. 5  illustrates sectional view of disc flange &amp; gutter spinning process, according to an embodiment herein; 
         FIG. 6  illustrates sectional view of gutter rolling process, according to an embodiment herein; 
         FIG. 7  illustrates sectional view of type seat and well area spinning process, according to an embodiment herein; 
         FIG. 8  illustrates sectional view of flange flare process, according to an embodiment herein; 
         FIG. 9  illustrates sectional view of flange forming process, according to an embodiment herein; 
         FIG. 10  illustrates sectional view of access hole [A/H] coining and piercing process, according to an embodiment herein; 
         FIG. 11  illustrates sectional view of shrinking process, according to an embodiment herein; and 
         FIG. 12  illustrates sectional view of machining and reaming process, according to an embodiment herein. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     The embodiments herein and the various features and advantageous details thereof are explained more fully with reference to the non-limiting embodiments and detailed in the following description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein. 
     As mentioned above, there is a need for a method to manufacture a vehicle wheel with a single work piece. The embodiments herein achieve this by providing a method for manufacturing a vehicle wheel without the need for reverse rolling or splitting of the work piece. Referring now to the drawings, and more particularly to  FIGS. 1 through 12 , where similar reference characters denote corresponding features consistently throughout the figures, there are shown preferred embodiments. 
     According to an embodiment, a method for manufacturing a vehicle wheel with a single work piece comprising the steps of, placing a metal band in a mandrel provided at a machining tool; forming the metal band/work piece for making a desired length of rim and a wheel disc; wherein size of the rim and the wheel disc can be formed according to the requirement; spinning a nave portion of the work piece for shaping the wheel disc; wherein the nave spinning of the work piece can be utilized to fix an inner width of the wheel; spinning the work piece for making a disc flange and a gutter portion of the wheel; rolling one end of the rim portion of the work piece that is connected to the wheel disc portion, to form the required gutter portion of predetermined shape and thickness; spinning the rim portion of the work piece further to form a tyre seat and well area; forming a flange flare by bending another end of the rim portion; forming the flange portion of the wheel rim by bending the flange flare to desired shape; machining flange edge, nave and bore to avoid sharp edges; reaming of bolt holes and chamfering bores at the wheel disk portion of the wheel. 
     According to an embodiment, before performing the spinning process for forming the gutter and disc flange portion of the wheel, bolt holes and a central bore is formed. Further, after forming the flange portion at another end of the rim portion, air hole for the wheel disc is pierced and coining the air hole is also performed. The machining process is performed for obtaining final desired shape of the wheel. 
       FIG. 1  illustrates sectional view of metal band  100  fixed onto a machining tool, according to an embodiment. The metal band  101  is placed in a mandrel  102  provided at a machining tool. The weight of the metal band is taken according to the wheel size requirement. 
       FIG. 2  illustrates sectional view  200  of first spin forming process, according to an embodiment. The metal band/work piece  101  is undergone first, forming process for making a desired length of rim  201  and a wheel disc  202 ; wherein size of the rim and the wheel disc can be formed according to the requirement. The metal band is bent to a predetermined angle  203  to form the desired wheel disc portion  202  with a predetermined thickness. 
       FIG. 3  illustrates sectional view of final spin forming process  300 , according to an embodiment. During final forming process the work piece is bent according to the required angle for making the wheel disc portion  301  and the wheel rim. 
       FIG. 4  illustrates sectional view of nave spinning process  400 , according to an embodiment. A nave portion  401  of the work piece is undergone for a spinning process for shaping the wheel disc; wherein the nave spinning of the work piece can be utilized to fix an inner width of the wheel. 
       FIG. 5  illustrates sectional view of disc flange &amp; gutter spinning process  500 , according to an embodiment. The work piece is further undergone for spinning process to make a disc flange  502  and a gutter portion  504  of the wheel. Before performing the spinning process for forming the gutter and disc flange portion of the wheel, bolt holes  503  and a central bore  501  is formed. 
       FIG. 6  illustrates sectional view of gutter rolling process  600 , according to an embodiment. The one end of the rim portion that is connected to the wheel disc portion is undergone for a rolling process to form the gutter portion  504  of required shape and thickness. During rolling process the weight of the rim portion get increased. 
       FIG. 7  illustrates sectional view of type seat and well area spinning process  700 , according to an embodiment. The rim portion of the work piece further undergone for a spinning process to form a tyre seat and well area  701 . The well area  701  has a reduced width compared to the rim portion. 
       FIG. 8  illustrates sectional view of flange flare process  800 , according to an embodiment. Using the forming process a flange flare  801  is formed by bending another end of the rim portion outwardly. 
       FIG. 9  illustrates sectional view of flange forming process  900 , according to an embodiment. The flange portion  901  of the wheel rim is formed by bending the flange flare  801  to a desired shape. 
       FIG. 10  illustrates sectional view of A/H coining and piercing process  1000 , according to an embodiment. Further, after forming the flange portion at another end of the rim portion, air hole  1001  for the wheel disc is pierced and coining of the air hole is also performed. 
       FIG. 11  illustrates sectional view of shrinking process  1100 , according to an embodiment. The length of the rim portion is reduced by a shrinking process. 
       FIG. 12  illustrates sectional view of machining and reaming process  1200 , according to an embodiment. The flange edge  1201 , nave  1202  and bore are undergone for a machining process to avoid sharp edges. The bolt holes are reamed and the bores at the wheel disk portion is chamfered accordingly. The machining process is performed for obtaining final desired shape of the wheel. 
     According to an embodiment, the novel method for manufacturing a vehicle wheel has simple fabrication techniques. Hence, the method does not utilize any for reverse rolling for obtaining a flange portion and does not require any splitting process for gutter formation. Further, the manufacturing a vehicle wheel can be performed at low cost. Hence the raw material requirement, wastage and labor charges are less compared to all other wheels manufacturing process. 
     The foregoing description of the specific embodiments will so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the embodiments as described herein.