ALLOY WHEEL

MANUFACTURIN
G
PRESENTED BY :NAME :- PANKAJ KUMAR DALAI
SEMESTER :- 8TH
REGD. NO. :- 11012251421
ROLL NO. :- 11-ME/76

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

INTRODUCTION
Alloy wheelsarewheelsthat are made from
analloyofaluminiumormagnesium. They are
typically lighter for the same strength and
provide betterheat conductionand improved
cosmetic appearance over steel wheels.

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.

Components Of Alloy
Wheel
Wheel hub.
Spokes.
Rim.

Reasons for using

Aluminum
Improved car
handling and riding comfort.
Improved grip.
Reduced fuel consumption.
Better braking performance.

PROPERTIES REQUIRED
Stiffness.
Yield Strength.
Temperature & Corrosion resistance.
Fatigue Strength.
Impact Resistance.
Reduced Weight.
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MANUFACTURING STEPS
Processes 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)

LOW PRESSURE DIE

CASTING

Metal stored in crucible.

The metal solidifies.

Air at Pressure(15-100 kPa) introduced.

Molten metal rises into the cavity
between the dies.
The pressure is released after which the
die is opened and casting taken out.
Setup for LPDC
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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.

Produces light and strong wheels at

reasonable costs.

Temp. increased to 300-3500C.

Steel rollers push against the rim area
to its final dimension.

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FORGING
Single 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

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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 OPERATIONS
Machining 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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COMPARISON
CAST WHEELS

FORGED WHEELS

Low cost of production.

Mediocre fatigue performance.

Could fail due to sudden impacts (hitting curbs and potholes).

Small variety of surface finishes can be applied.

Better mechanical properties than cast wheels.

Higher safety due to absence of pores and cavities.

Can perform with forged wheels under normal loading conditions.

Relatively expensive.

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 POLISHING
Very 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.
FABRICATION
Assembly 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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THANK YOU !!

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