EP3131690B1 - Method for producing wheel disc forms on flow-forming machines - Google Patents

Method for producing wheel disc forms on flow-forming machines Download PDF

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Publication number
EP3131690B1
EP3131690B1 EP15728148.6A EP15728148A EP3131690B1 EP 3131690 B1 EP3131690 B1 EP 3131690B1 EP 15728148 A EP15728148 A EP 15728148A EP 3131690 B1 EP3131690 B1 EP 3131690B1
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EP
European Patent Office
Prior art keywords
disc
zones
flow
wheel disc
margin
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EP15728148.6A
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German (de)
English (en)
French (fr)
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EP3131690A1 (en
Inventor
Matthias Gruetgen
Carlos Eduardo LOPES
Marcelo Yumoto GRAZIANI
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Maxion Wheels Holding GmbH
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Maxion Wheels Holding GmbH
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Publication of EP3131690A1 publication Critical patent/EP3131690A1/en
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D22/00—Shaping without cutting, by stamping, spinning, or deep-drawing
    • B21D22/14—Spinning
    • B21D22/16—Spinning over shaping mandrels or formers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D53/00—Making other particular articles
    • B21D53/26—Making other particular articles wheels or the like
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D53/00—Making other particular articles
    • B21D53/26—Making other particular articles wheels or the like
    • B21D53/265—Making other particular articles wheels or the like parts of wheels

Definitions

  • the invention relates to a method for producing wheel disc forms, which have an attachment flange, a disc transition surface and a disc margin, for vehicle wheels from preferably metallic preforms on a flow-forming machine which has a spinning mandrel which is rotatable about an axis of rotation, and at least one spinning roller, which is adjustable radially relative to the axis of rotation, for the flow forming of the preform against the spinning mandrel and production of a flow-formed transition surface on the wheel disc form, according to the preamble of claim 1.
  • a preform such as for example a ring-shaped planar blank
  • a preform such as for example a ring-shaped planar blank
  • the central hole, the bolt holes and ventilation holes are then punched out in order, in a rapid manufacturing cycle, to produce a wheel disc with attachment flange, transition surface and disc margin, which wheel disc is connected to a separately produced wheel rim part preferably by way of welded connections between disc margin and wheel rim inner side in order to produce a vehicle wheel for utility vehicles or passenger motor vehicles.
  • the entire flow-forming process in a flow-forming machine is performed in one chucking operation and normally by means of multiple spinning rollers which are controlled independently of one another in terms of motion and which perform shape-changing work in succession.
  • the applicant for example, uses a flow-forming machine with three spinning rollers by means of which the preform is, from the outside, pressed and flow-formed against the forming contour of a spinning mandrel which is rotatable about a horizontal axis of rotation.
  • the wheel disc form In the chucking region of the preform between a face side of the spinning mandrel and a holding-down means, the wheel disc form has the initial thickness of the preform, whereas the transition surface and the disc margin are flow-formed and are correspondingly provided with a wall thickness which is reduced in relation to the initial thickness of the preform and which decreases toward the disc margin in a manner dependent on the distance from the chucking region.
  • the wheel disc forms produced by the applicant in accordance with this method are, after the punching of the ventilation holes and punching or drilling of the bolt holes on the attachment flange, subjected to material removal by turning with cutting action by a few 1/10 mm both at the inside and at the outside, and also, the disc margin is subjected to material removal by turning to this extent on the outer side, in order to achieve optimized planar abutment of the vehicle wheel against a vehicle hub, and also in order to improve the contraction of the wheel disc, with the disc margin uniformly rounded on the outer side by the material removal by turning, in the separately manufactured wheel rim part.
  • the applicant also performs reworking of the disc margin and of the central hole on the wheel disc form.
  • rotationally symmetrical wheel disc forms are produced which have uniform surfaces on the inner side and on the outer side and an improved matrix structure in particular in the flow-formed transition surface, via which all of the forces and loads must be transmitted between wheel rim and vehicle hub while a vehicle is in motion.
  • a further advantage of the flow forming or metal spinning process lies in the material saving in relation to wheel discs produced for example by deep drawing.
  • EP 1 473 097 B1 proposes for example that the preform be produced from a rectangular metal strip, which is pre-rolled by cold rolling to form a partial circular ring, is subsequently deformed into a conical band by roll bending and, after the welding of the ends of said band, is provided with the attachment flange on a flow-forming machine.
  • EP 2 556 895 A1 discloses a separation disc for centrifugal separators and a method for manufacturing such separation discs.
  • the separation discs are intended to be arranged in a stack of similar separation discs, for which purpose they receive by the manufacturing process, a pattern of small size, spacing members, to provide equidistant interspaces of separation discs in the stack.
  • a mandrel against which the material of the separation disc preform is spinned during manufacture receives deformations, leading to corresponding spacing members on the separation disc.
  • US 2012/0177879 A1 refers to drums with a tooth profile.
  • the drum is produced in a flow forming process against the mandrel, which mandrel comprises channels and protuberances to define a tooth profile in the flow formed part.
  • windows can be formed either by a punching process or by a machining process.
  • a method for producing wheels by roll forming to obtain wheels as laid down in the preamble of claim 1 is known from EP 2 460 603 A1 .
  • the known method aims to produce wheels having a uniform mass in the axial direction and in the circumferential direction, resulting in high dynamic balance precision.
  • the preform is flow-formed against a spinning mandrel which has multiple local elevations arranged so as to be distributed over the circumference in order to generate zones which are formed so as to be distributed over the circumference of the wheel disc form and which have material reductions in the flow-formed transition surface of the wheel disc form.
  • the invention is consequently based on the basic concept of generating, during the flow forming or metal spinning process, not a uniformly rotationally symmetrical wheel disc form but a wheel disc form which is non-uniform in the circumferential direction, and on which, by means of the spinning mandrel, material reductions are created or generated in regions of the finished vehicle wheel which are removed in order to realize ventilation holes.
  • zones with material reductions could also be generated in the disc margin, or, by depressions in the mandrel, zones with material accumulations could also be generated in the flow-formed transition surface or in the disc margin.
  • the material that is additionally displaced by pressing or rolling in the region of the material reductions can not only be used for generating the material accumulations, but can at the same time also contribute to a situation in which the preform is provided with smaller initial dimensions than a preform without zones with material reductions which is converted into a wheel disc form on the flow-forming machine.
  • Ventper holes are formed in the wheel disc form by way of a punching or cutting process, wherein said ventilation holes are preferably formed in the transition surface of the wheel disc form between zones with material reductions or alternatively between zones with material accumulations. It is particularly advantageous if, during the flow-forming against the spinning mandrel, material reductions are created in zones of the transition surface which, in a subsequent method step, are removed in a punching or cutting process for the production of ventilation holes.
  • the particular advantage of this embodiment lies in the fact that, already during the flow-forming of the wheel disc form, material reductions are created in regions which will be removed at a later point in time in any case during the punching or cutting of the ventilation holes.
  • the larger the ventilation holes will be on the finished vehicle wheel the more material can be displaced out of said regions and into other regions situated further remote on the wheel disc in the flow-forming direction, that is to say generally into regions situated radially further to the outside.
  • the internal pressure in the vehicle tyre is generated and altered by way of a valve.
  • Said valve by way of its valve mass, generates an imbalance on the vehicle wheel. Since, in modern vehicle wheels, use is made of valves with integrated air pressure measurement sensor, this additional weight is generally compensated by way of balancing weights required for this purpose.
  • zones with material accumulation and/or zones with material reduction are generated so as to alternate in the circumferential direction.
  • zones with material accumulation are created in each case so as to be offset with respect to one another in the circumferential direction, which zones with material accumulation are then each adjoined by a zone with the material thickness that the wheel disc has imparted to it in any case by the flow-forming process; it is then consequently not necessary, albeit possible, for an additional zone with material reduction to also be created in each case between zones with material accumulation in the disc margin.
  • the ventilation holes are produced in the correct regions which are predefined or determined by the non-uniform wheel disc contour attained according to the invention, in particular the material accumulations and material reductions.
  • the method is used to procude a vehicle wheel, and a wheel disc part after the production of the ventilation holes.
  • at least one zone with material reduction generated during the flow forming is formed on the inner side or the outer side of the transition surface between adjacent ventilation holes and/or between the ventilation holes at the disc margin and/or at the disc margin in an axial elongation of each ventilation hole.
  • the basic concept is that, already during the flow-forming, a uniform material thickness is not generated all the way around in the circumferential direction, but instead, material is saved by way of zones with different material thicknesses, and/or regions that are subjected to structurally greater or different loading are strengthened by way of zones with material accumulations.
  • At least one zone with material reduction preferably at least one rib-shaped or broad strip-shaped zone with material reduction, is formed on the transition surface between adjacent ventilation holes in the circumferential direction.
  • This refinement utilizes the fact that the webs that remain between the ventilation holes do not require a large material thickness over their entire axial extent along the transition surface, and instead, it suffices there for only certain regions, in particular regions around the ventilation holes, to have an adequate material thickness. Outside said regions, it is thus possible for material to be saved, and for said material to then be used again for generating zones with material accumulation, primarily in the disc margin.
  • At least one zone with material accumulation preferably at least one strip-shaped zone with material accumulation, is formed on the transition surface so as to be offset in the radial and axial direction toward the disc margin relative to the ventilation holes, and/or in that in each case at least one zone with material accumulation, preferably at least one strip-shaped zone with material accumulation, is formed at the disc margin in an axial and radial elongation of the ventilation holes.
  • the marginal region, which is in effect situated in the shadow of the ventilation holes, of the disc is reinforced in relation to regions situated between the ventilation holes in an elongation of the webs, whereby in particular, on the finished vehicle wheel, in which the disc connection to the wheel rim is realized by way of weld seams, an improved material distribution and at the same time lower loading of the weld seams are achieved.
  • At least one zone with material accumulation may be formed at the transition between transition surface and disc margin, in each case between adjacent ventilation holes.
  • the disc margin which is normally perpendicular or approximately perpendicular to the attachment flange and which thus runs in substantially cylindrical fashion about the wheel axis, is additionally stiffened in relation to the transition surface by way of this measure, which improves the fatigue strength of vehicle wheels.
  • each web-like zone with material accumulation or in each case exactly two web-like zones with material accumulation is/are formed between adjacent ventilation holes, wherein preferably each web-like zone originates at a point offset in the circumferential direction adjacent to a ventilation hole and/or two web-like zones arranged to both sides of a ventilation hole lie with a 90° angular offset with respect to one another relative to the central point of said ventilation hole.
  • the web-like zones consequently effect local additional stiffening between disc margin and transition surface.
  • the material accumulations and/or material reductions are formed on the inner side of the transition surface or of the wheel disc.
  • a corresponding wheel disc form for a vehicle wheel of said type is consequently generated by virtue of the preform being rolled or flow-formed against the outer contour of a spinning mandrel, whereby it is then possible for the material accumulations or material reductions to be formed only on the subsequent inner side of the wheel disc or of the wheel disc form.
  • the ventilation holes do not have to be of circular form, but may also be of oval, V-shaped or a window-like form, thus resulting in corresponding profiles of the ventilation hole margins.
  • the zones with material accumulations or material reductions each have marginal edges running in the radial direction and delimiting edges running in the circumferential direction. It is particularly advantageous if in each case the two marginal edges of a zone run obliquely or in curved fashion with respect to the wheel axis and the spacing between the marginal edges increases toward the disc edge.
  • the inner diameter of a wheel disc generally increases continuously from the attachment flange to the disc margin, if material accumulations or material reductions are generated, it must however additionally be ensured that the wheel discs can be pulled off the spinning mandrel, which is improved by way of marginal edges which run obliquely or in curved fashion.
  • the forming contour of a spinning mandrel can be equipped with multiple local elevations and/or depressions arranged so as to be distributed over the circumference in order, during the flow-forming process, to generate multiple zones which are formed so as to be distributed over the circumference of the wheel disc form and which have material accumulations or material reductions.
  • the depressions or elevations on the spinning mandrel then generate the material accumulations or material reductions in the transition surface, which is flow-formed against the spinning mandrel by means of the spinning rollers, of the wheel disc or of the wheel disc form.
  • a corresponding spinning mandrel normally has a face wall which interacts with a holding-down means on the machine, in the region of which face wall flow-forming cannot be performed, whereby, in a preferred refinement, said region is then used for generating the attachment flange on the wheel disc form, and a side wall as a forming contour for the forming of the transition surface and the disc margin.
  • the side wall is equipped with multiple elongate elevations arranged so as to be distributed uniformly over the circumference of the side wall, wherein preferably, a circular, oval or U-shaped elevation is formed between elongate elevations formed so as to be offset circumferentially relative to one another.
  • the circular, oval or U-shaped elevation then serves for realizing material reductions in regions in which the ventilation holes will subsequently be generated, whereas the further elongate elevations exist in those regions in which, subsequently, the transition surface of the wheel disc connects the disc margin between the ventilation holes to the attachment flange in web-like fashion.
  • the side wall as a forming contour for the disc margin, may be formed with multiple ring segment-shaped depressions which are arranged so as to be distributed uniformly over the circumference of the side wall and which extend in the circumferential direction, wherein preferably, in each case one ring segment-shaped depression is arranged axially offset with respect to a circular, oval or U-shaped elevation formed on the side wall and/or is arranged axially offset and circumferentially offset with respect to the elongate elevations.
  • the ring segment-shaped depressions consequently serve for realizing material accumulations in those regions of the disc margin which, on the wheel disc, lie in an axial elongation of a ventilation hole after the punching of the ventilation holes.
  • the side wall may be equipped with multiple circular ring-shaped, ring-shaped, strip-shaped or partially ring segment-shaped and strip-shaped elevations which are distributed uniformly with respect to one another and over the circumference and which serve for the forming of zones with material reductions between punched or cut regions for ventilation holes.
  • the depressions or elevations have margins which run in the axial direction of the spinning mandrel, which margins preferably run obliquely and/or in curved fashion such that the spacing between the margins increases in the flow-forming direction.
  • the zones with material accumulation in the transition surface, or in the disc margin at least partially have a greater material thickness than the material thickness in the regions surrounding said zones, and/or if the zones with material reduction in the transition surface, or in the disc margin, at least partially have a smaller material thickness than the material thickness in those regions of the transition surface which surround said zones. Consequently, where reference is made here to material accumulation or material reduction, this may be realized already by virtue of the wheel disc form, as viewed in the circumferential direction, being provided with a smaller material thickness in the region of the material reduction than in the adjacent regions, or being provided with a greater material thickness in the region of the material accumulation than in the adjacent regions.
  • the change in material thickness should in this case be appreciable, that is to say should amount to at least 3% or 5% or 10%, or more, of the initial thickness of the preform, and/or should amount to more than 5%, preferably more than 10% or 15%, relative to adjacent zones.
  • Figure 1 in schematically highly simplified form for the purposes of explaining the method sequence during the flow-forming of preforms to form wheel disc forms or wheel discs, the reference sign 1 denotes a flow-forming machine. Only those machine parts of the flow-forming machine 1 which are of particular importance for the flow-forming process are illustrated, specifically a main spindle 2 that can be driven for example by way of a gearing (not shown), a spinning mandrel 3 which is connected rotationally conjointly and in exchangeable fashion to the main spindle 2 and which has the negative contour of the wheel disc form 70 to be produced, a holding-down tool 4, and multiple spinning rollers 5.
  • a main spindle 2 that can be driven for example by way of a gearing (not shown)
  • a spinning mandrel 3 which is connected rotationally conjointly and in exchangeable fashion to the main spindle 2 and which has the negative contour of the wheel disc form 70 to be produced
  • a holding-down tool 4 and multiple spinning rollers 5.
  • two spinning rollers 5 are shown, which are controlled independently of one another in accordance with a predefined rolling programme and which, temporally in succession, cause a preform 6, which in the case of the method implementation illustrated is composed of a cylindrical sheet-metal blank 6 with a predefined uniform material thickness of for example 14 mm, to be pushed against the outer contour or forming contour of the spinning mandrel 3, which can be rotated at high rotational speed about the axis of rotation D by means of the main spindle 2, and flow-formed.
  • a preform 6 which in the case of the method implementation illustrated is composed of a cylindrical sheet-metal blank 6 with a predefined uniform material thickness of for example 14 mm
  • the flow-forming machine 1 may preferably have three or four spinning rollers 5, wherein the spinning rollers may have different diameters and different contours than one another in order to achieve an optimum result of the flow-forming of a wheel disc or wheel disc form 70.
  • the illustration in figure 1 serves merely for visualization, as the method according to the invention may in principle be performed on any flow-forming machine which is suitable for the manufacture of wheel disc forms or wheel discs by means of flow forming or metal spinning.
  • Figure 2 shows a spinning mandrel 3 for the production of a wheel disc form 70 or a wheel disc 10 as illustrated in Figures 3 to 6 .
  • wheel disc form is used for the intermediate product which is present after the flow-forming process and which duly already substantially has the contour of the final wheel disc, but without subsequent cutting of the wheel margin and of the central hole having been performed, and before the punching, cutting and/or drilling processes for producing the ventilation holes and the bolt holes have been performed.
  • wheel discs it is at least the case that the punching or cutting processes for the ventilation holes have already been performed, and it is preferably also the case that the marginal edges of the central hole and of the disc margin have then been subjected to reworking (for example cutting, deburring) and the bolt holes for wheel bolts have also been drilled or cut.
  • the surface of the wheel disc may be mechanically reworked, beaten flat and/or stamped in order that the wheel disc, as disc part, can be connected to a wheel rim part to form a vehicle wheel. Mechanical reworking may in particular be performed by way of cutting processes on the attachment flange (if appropriate on both sides) and at the disc margin (on the outer side) before the wheel disc is connected to the wheel rim part to form the vehicle wheel.
  • Figure 2 shows a spinning mandrel 3 according to the invention for the production of the wheel disc 10 according to the invention as per a first design alternative, as shown in Figure 3 , on the flow-forming machine 1 shown for example in Figure 1 .
  • the wheel disc 10 serves preferably for the production of a vehicle wheel for a utility vehicle, for which reason it has a relatively large central hole 11 around which there is formed an attachment flange 12 equipped with a total of ten bolt holes 21, said attachment flange being formed by the nondeformed surface part of the preform (blank 6 in Figure 1 ).
  • the attachment flange 12 merges integrally into a conically widening disc transition surface 13 which ends in a substantially cylindrical or ring-shaped disc margin 14 with a central point that coincides with the wheel axis R.
  • the attachment flange 12, the disc transition surface 13 and the disc margin 14 are formed by flow-forming of the preform against the spinning mandrel 3 shown in Figure 2 , wherein substantially only the transition surface 13 and the disc margin 14 are deformed during the flow-forming, that is to say are flow-formed.
  • the spinning mandrel 3 illustrated in Figure 2 correspondingly has a face wall 7 and a side wall 8 which has two different sections, wherein that section 8A of the side wall 8 which directly adjoins the face wall 7 running perpendicular to the axis of rotation of the spinning mandrel 3 serves for the generation of the disc transition surface on the wheel disc 10 or wheel disc form, and for this purpose, said section correspondingly widens conically in the flow-forming direction.
  • the first section 8A is then adjoined by a second section 8B of the side wall 8, which during the flow-forming process serves for generating the disc margin (14 in the case of the wheel disc 10 or wheel disc form).
  • the preform 6 which is in this case of ring-shaped form lies, as indicated in Figure 1 , by way of an inner sub-section against the face wall 7 of the spinning mandrel 3 and is pressed against the face wall 7 by means of the holding-down tool (4 in Figure 1 ).
  • the holding-down means 4 must be adequately supported on the preform 6 in the region of the face wall 7 of the spinning mandrel 3, no deformation of the preform can be performed in this sub-region during the flow-forming by way of the spinning rollers 5.
  • the spinning mandrel 3 has, in the section 8A of the side wall 8, multiple local elevations 41 distributed over the circumference, said elevations in this case being circular, wherein the spinning mandrel 3 in Figure 2 is equipped, in each case between two adjacent local circular elevations 41, with a further, strip-shaped elevation 42.
  • a circular elevation 41 and a strip-shaped elevation 42 alternate in each case on the section 8A of the side wall 8 of the spinning mandrel 3.
  • the elevations 41, 42 on the form or contour of the spinning mandrel 3 have the effect that, during the flow forming, on the wheel disc form or wheel disc 10 as per Figure 3 , the disc transition surface 13 is provided with circular zones with material reductions, said zones being distributed uniformly over the circumference of said disc transition surface, specifically at all locations where the spinning mandrel 3 has a circular elevation 41; furthermore, during the flow-forming process, the transition surface 13 is provided, in each case between two such circular zones with material reduction, with in each case one strip-shaped zone 15 with material reduction, specifically where the strip-shaped elevations 42 are formed on the spinning mandrel 3; during the flow-forming against the outer contour of the spinning mandrel 3, the zones 15 with material reduction have an effect exclusively on the inner side 16 of the wheel disc 10, specifically by virtue of the fact that the thickness of the disc wall between the inner side 16 of the wheel disc 10 and the outer side 17 is smaller in the region of a zone
  • the extent of the thickness reduction is determined by the dimension of the height of the elevations 41 and 42 on the spinning mandrel 3.
  • the outer side 17 of the wheel disc has, as can be clearly seen in Figure 4 , a rotationally symmetrical contour, because, during the flow forming, the spinning rollers (5 in Figure 1 ) bear against the outer side 17, and perform the deformation work, while the spinning mandrel with the preform rotates at high rotational speed.
  • FIG. 5 shows the state of a wheel disc form 70 after the flow forming and before the removal of the punched slugs 71 in order to produce the ventilation hole 18 with an, in this case, circular ventilation hole margin 88 in the flow-formed transition surface 13.
  • the correspondingly circular zones 72 with material reduction generated on the wheel disc form 70 by means of the circular elevations 41 on the spinning mandrel 3 can be clearly seen.
  • the spinning mandrel 3 as per Figure 2 furthermore has, in the section 8B of the side wall 8, and consequently in the section which serves for generating the disc margin 14 on the wheel disc 10 during the flow-forming process, a local depression 46 in each case in a radial, axially parallel elongation of the region in which the circular elevations 41 are formed, wherein, on the section 8B, between two regions with local depression 46, there is formed in each case one region 47 which lies in an elongation of the strip-shaped elevation 42, said region being implemented either as a local elevation or else as a zone with a cylindrical surface (that is to say without elevation or depression).
  • This specific shaping of the side wall 8B has the effect, during the flow forming of the preform against the spinning mandrel 3, that the disc margin 14, as can already be clearly seen in Figure 3 , is provided, in each case in an elongation of a ventilation hole 18, that is to say in effect behind or in the shadow of a ventilation hole 18, with a disc margin section 19 as a zone with material accumulation; by contrast, in an axial elongation of the intermediate region 24 equipped with the strip-shaped zone 15 between two ventilation holes 18, there is formed a disc margin section 20 which is substantially the same material thickness as the sections of the wheel disc 10 in regions where the spinning mandrel 3 had neither elevations nor depressions.
  • the ventilation holes 18 are punched only after the disc margin sections 19 of relatively large material thickness have already been formed during the flow-forming process, and that the disc margin sections 20 could also be provided with a slightly reduced material thickness in relation to other regions of the transition surface.
  • zones 72 with material reductions have been created, by way of the circular elevations 41 on the spinning mandrel, in the region of the punched slugs 71 that will later be removed in order to produce the ventilation holes 18, and also by virtue of the fact that a strip-shaped zone 15 with material reduction is created in each case in intermediate regions 24 between two ventilation holes 18, it is correspondingly possible for more starting material to flow into the disc margin 14 during the flow-forming process, whereby the preform for the production of the wheel disc form 10 can, for an identical wheel disc width to be produced, be provided with a smaller outer diameter than a preform used for the flow-forming of a wheel disc of the same disc width but without material reduction.
  • the wheel disc 10 has a weight reduction imparted to it by the strip-shaped material reductions 15 between two ventilation holes 18, and at the same time has a structural reinforcement imparted to it by the strip-shaped or rib-shaped configuration, wherein the weight savings attained in the zones 15 by way of material reductions are greater than the increase in material owing to the zones 19 with material accumulation at the disc margin 14.
  • the material accumulations in the sections 19 at the disc margin 14 including the interposed sections 20 with at least smaller material thickness, and possibly even reduced material thickness, in relation to that in the sections 19.
  • the wheel disc 10 for a utility vehicle wheel has, in the exemplary embodiment shown in Figures 3 to 10 , ten bolt holes 21 in the attachment flange 12, ten ventilation holes 18 and correspondingly also ten strip-shaped zones 15 with material reductions as stiffening ribs on the inner side 16 of the transition surface 13.
  • Each strip-shaped zone 15 with material reduction in the wheel disc 10 has in each case two marginal edges 15A running in the radial direction, wherein each marginal edge 15A runs obliquely with respect to the wheel axis R, and furthermore, the distance A between the marginal edges 15A increases preferably in continuous fashion toward the disc margin 14.
  • the material thickness D1 in the region of the attachment flange 12, which corresponds to the initial thickness of the preform at least before any material removal by turning of the base surfaces of the attachment flange 12, is considerably greater than the material thickness D2 in the disc transition surface 13, for example at the margin of a ventilation hole 18 (compare Figure 6 ).
  • the material thickness D2 is at a minimum normally approximately 30-40% of the initial thickness D1, and lies rather in the range of approximately 40-50% of the initial thickness D1.
  • the material thickness D3 decreases considerably once again, as can be seen particularly clearly both in the sectional view in the upper half of Figure 4 and also in the sectional view in Figure 6 .
  • the material thickness D3 may locally amount to for example only 60% to 80% of the material thickness D2 in the surrounding flow-formed regions of the transition surface, and may possibly amount to only approximately 10% to 30% of the material thickness D1 in the attachment flange 12.
  • the material thickness is D2.
  • the sectional view in Figure 4A illustrates the material accumulation at the disc margin 14 in an (in this case central) radial elongation of the ventilation holes 18.
  • the dotted line in the detail view in Figure 4A indicates the material thickness D2, that is to say the material thickness that the disc margin 14 is provided with during the flow-forming process in the region of the sections 20 which are duly flow-formed but which are not thickened by way of material accumulation. Since zones 20 with material accumulation are formed in the disc margin 14 by means of the depressions (46, Figure 2 ) on the spinning mandrel, the disc margin 14 is locally provided with a material thickness D4 which is greater than the material thicknesses D2 and D3.
  • the (maximum) material thickening D4 which preferably amounts to 5 to 10% in relation to the adjoining regions with the material thickness D2, is smaller than the (maximum) material thinning D3, which preferably amounts to 10 to 30% relative to the adjoining regions with the material thickness D2.
  • the minimum material thickness D5 it is in turn possible for the minimum material thickness D5 to be reduced yet further, as the entire slug is removed.
  • the relative relationships may, at the end of the flow-forming process, be defined approximately as follows: 1.2 ⁇ D4 / D2 > 1 1 > D3 / D2 ⁇ 0.7
  • the attachment flange 12 may be subjected to material removal by turning with cutting action on both sides, for example by 0.3 mm on each side, and the disc margin 14 may also, at least on the outer side, be subjected to material removal by turning with cutting action by for example 0.1 mm to 0.5 mm, or subjected to other reworking, such that then, on the finished vehicle wheel or disc part, the disc margin 14 has no changes in thickness or only minimal changes in thickness, which however existed with greater differences in the wheel disc form as an intermediate product of the manufacturing process.
  • said wheel disc is a wheel disc 110 for a utility vehicle wheel with ten bolt holes 121 in the attachment flange 112 and ten ventilation holes 118 in the disc transition surface 113 that has been flow-formed against a spinning mandrel (not shown) during the flow-forming process, and it is preferably also the case, as in the preceding exemplary embodiment, that the disc margin 114 has, in each case in a radial elongation of a ventilation hole 118, sections 119 which have a greater material thickness than sections 120 at the disc margin which lie in an elongation of an intermediate section 124 between two ventilation holes 118, as illustrated in the right-hand half of Figure 7 .
  • the main difference between the wheel disc 110 as per Figure 7 and the preceding exemplary embodiment lies in the shapes of the zones 115 with material reductions in the intermediate section 124 between two ventilation holes 118.
  • the zone 115 with material reductions has three areas 131, 132, 133 which are delimited with respect to one another, wherein each of said areas has a material thickness D3 smaller than the initial thickness D1 of the preform, as remains present in the attachment flange 112 of the wheel disc 110.
  • the material thickness D3 is also smaller than the thickness D4 in the region of the sections 119 at the disc margin 114, in the form of zones with material accumulation, and is also smaller than the thickness D2 in the region of those sections of the wheel disc transition surface 113 which surround the areas 131, 132, 133.
  • the area Perpendicular to the wheel axis R, the area has delimiting edges 141, 142, the area 132 has delimiting edges 143, 144, and the area 133 has delimiting edges 145, 146, the length of which increases, in each case from the smallest length of the delimiting edge 141 to the greatest length at the delimiting edge 146, correspondingly to the increase in width of the areas 131, 132, 133.
  • each area 131, 132, 133 has a distinct zone with substantially constant reduced thickness D3, whereas, in particular in the region of the marginal edges 134-138 and the delimiting edges 141-146, the thickness changes continuously to the material thickness D2 in that region of the transition surface 113 which surrounds the ventilation holes 118 or the areas 131, 132, 133.
  • the intermediate section 124 between two ventilation holes 118 being broken up by areas, with a zone 115 with material reduction being realized in or with each area 131, 132, 133, it is correspondingly the case that a greater amount of material is provided which can flow into the disc margin 114 during the flow-forming process.
  • the multiple areas 131-133 serve to realize a reduction in the overall weight of the wheel disc
  • the intermediate webs 151 and 152 that remain between two adjacent areas 131, 132 serve to generate, between areas 132, 133, additional stiffening of the region between two ventilation holes 118 and of the disc transition surface 113 as a whole.
  • a total of ten bolt holes 121 and one central hole 211 are formed on the attachment flange 212, with ten ventilation holes 218 and ten zones 215 with material reductions being formed in each case between two ventilation holes 218 in the disc transition surface 213 that has been flow-formed during the flow-forming process.
  • the upper delimiting edges 241 of each zone 215 with material reduction lie above the region of extent of the ventilation holes 218.
  • the delimiting edge 241 together with the marginal edges 235 of the zones 215 extend partially, as viewed in the radial direction, to a point in front of the ventilation holes 218.
  • Each zone 215 consequently has a corner region 251 between the marginal edge 235 and that marginal edge 241 which is closer to the attachment flange, which corner region causes the intermediate section 224 between two ventilation holes 218 to be narrowed to the relatively small material thickness D3, which has the result not only that additional material is moved away out of the region between the ventilation holes 218 and the attachment flange 212 in the region of the transition surface 213, but at the same time that the rigidity of the disc transition surface 213 is reduced slightly also above the ventilation holes 218 (as seen in Figure 10 ), which improves the continuous loading capability of the disc transition surface 213, which is, owing to ventilation holes 218, in any case of non-uniform flexural stiffness.
  • the lateral delimiting edges 235 of the zones 215 run in straight form from the disc margin 214 to a point slightly above the centre of the ventilation holes 218, and above this, proceeding from the upper delimiting edge 241 of the zone 215, run in curved fashion, in this case partially even with the same radius of curvature as that of the ventilation holes 218 (which will be punched out at a later point in time).
  • the lower delimiting edge 242 lies substantially at the level of the lower tangent to each ventilation hole 218; the lower delimiting edge 242 could also lie lower and thus closer to the disc margin 214.
  • Figures 12 and 13 show a fourth exemplary embodiment of a wheel disc 310 with attachment flange 312, disc transition surface 313 that has been flow-formed during the flow-forming process, and disc margin 314.
  • the ventilation holes 318 have already been formed in a punching or cutting process subsequent to the flow-forming step.
  • the disc transition surface 313 is provided, up to a point close to the lower margin of the individual ventilation holes 318, with a constant diameter all the way around, self-evidently interrupted by the ventilation holes 318 that are punched out in certain regions.
  • a spinning mandrel for the production of the wheel disc 310 has elevations on the spinning mandrel in those regions which are to be cut out or punched out at a later point in time to form ventilation holes 318, which elevations correspondingly lead to zones with material reductions on the inner side of the wheel disc form for the wheel disc 310, because, since said regions can be punched out as ventilation holes 318, it is possible for the material saved by way of the material reduction to be used for generating sections with material accumulation, for example also at the disc margin 314 preferably in a radial elongation of the individual ventilation holes 318.
  • two projecting webs 351 per ventilation hole 318 said webs forming zones with material accumulation, are formed on the disc inner side 316 so as to be distributed over the inner circumference, wherein each of said webs 315, as can be clearly seen in particular also from Figure 13 , originates on the inner side 316 of the transition surface 313 in the region of the disc transition surface 313 and extends into the region of the disc margin 314.
  • two webs 351 as zones with material accumulation are provided per ventilation hole 318, and there are consequently twice as many webs 351 as ventilation holes 318.
  • the two webs 351 assigned to a respective ventilation hole 318 have the same angular spacing to a radial plane which bisects a ventilation hole 318 and simultaneously extends through the wheel axis R.
  • the angular spacing from one web 351 to the next but one web 351 is dependent on the number of ventilation holes 318, and is in each case equal among the webs, whereby overall, a symmetrical distribution of the pairs of webs 351 over the circumference is realized.
  • the wheel disc 410 shown in Figures 14 to 17 has also been produced by flow-forming of a circular blank against a spinning mandrel on a flow-forming machine, but not by flow-forming of a plate-type blank against the outer contour of a spinning mandrel, and instead by flow-forming of a blank that has been pre-formed into a pot shape against the inner contour of a correspondingly hollow-domed spinning mandrel.
  • the wheel disc 410 has a rotationally symmetrical inner side 416, whereas on the outer side 417 of the transition surface 413 of the wheel disc 410, a zone 415 with material reduction has been generated between every two ventilation holes 418.
  • the attachment flange 412 forms the holding-down surface for the preform, which is however subjected to pre-rolling or pre-drawing before the flow-forming process such that it can be inserted, for example in the form of a pot, into the cavity of a spinning mandrel.
  • the transition surface 413 is rolled, and in the process flow-formed, by way of flow-forming action against the inner side 416, against the inner wall of the spinning mandrel, whereby the outer side 417 of the transition surface 413 and of the disc margin 414 is provided with the inner contour of the spinning mandrel; the spinning mandrel has, owing to the method implementation, the negative shape of the outer side 417 of the wheel disc 410.
  • Ten ventilation holes 418 have been punched out in the transition surface 413 by punching after the flow-forming process, wherein each ventilation hole 418 is, during the punching process, positioned such that a zone 415 with material reduction is positioned symmetrically between in each case two adjacent ventilation holes 418.
  • the material thickness D3 in the region of the zones 415 with material reduction is considerably smaller than the thickness D2 in the other flow-formed regions of the disc transition surface 413.
  • the zone 415 with material reduction forms in each case a lens-shaped recess on the outer side 417 of the transition surface 413, wherein all of the zones 415 or recesses extend substantially in a band along the circumference in which the ventilation holes 418 have also been punched out.
  • the disc margin 414 it is possible in this refinement, too, for the disc margin 414 to be provided with sections with zones with material accumulation in particular in a radial elongation of the ventilation holes 418, whereas the sections in a radial elongation of the lens-shaped zones 415 with material reduction are provided either with the other material thickness D2 or with a material thickness further reduced in relation thereto.
  • Figures 18 to 20 show a vehicle wheel 550 in which a wheel disc 510 produced by flow-forming in accordance with the method according to the invention is connected to a wheel rim part 560 of arbitrary type of construction by way of the disc margin 514 of the wheel disc 510.
  • the wheel rim part 560 is in this case provided, in the flank of a safety hump 561, with a valve hole for receiving a valve 562, which gives rise to an imbalance of the vehicle wheel 550 as the latter rotates.
  • the wheel disc 510 is equipped with two zones 590 with material accumulation, wherein the additional mass created by the two material accumulation zones 590 on the inner side 516 of the transition surface 513 is coordinated with the overall weight of the valve 562 and the position thereof relative to the wheel axis.
  • the wheel disc 510 and the wheel rim part 560 are connected to one another such that the valve hole for the valve 562, and thus also the valve 562, lie centrally in relation to one of the ventilation holes 518.
  • a ventilation hole 518 is in turn situated on the inner side of the wheel disc 510 situated opposite the valve 562.
  • the two stud-like zones 590 with material accumulation as balancing weights for the valve 562 are thus formed integrally in the transition surface 513 to both sides of said ventilation hole 518 which is situated opposite the valve hole or valve 562, in this case exactly centrally between in each case two ventilation holes 518.
  • the two zones 590 with material accumulation may in this case serve, in a subsequent punching step, as a marker for setting the position of the wheel disc 510 in relation to the punching tools in order that the ventilation holes 518 are in each case punched out with the correct angular spacing to the zones 590.
  • the wheel disc 510 has no further separately implemented zones with material accumulation or material reduction.
  • the disc margin is formed, in sections, with zones with material accumulation in a radial elongation of the individual ventilation holes 518, wherein, in each case in a radial elongation of the intermediate section 524 between two ventilation holes, sections are formed on the disc margin 514 which either form zones with material reduction or which have the same material thickness as the "normal" regions of the transition surface 513.
  • a zone with material reduction (not shown) is provided in each case in that region of the disc transition surface 513 in which the ventilation holes 518 will be punched out at a later point in time, in order that the material saved there can be displaced into the disc margin 514 and/or can be used as material for the zones with material accumulation.
  • a zone with material reduction (not shown) is provided in each case in that region of the disc transition surface 513 in which the ventilation holes 518 will be punched out at a later point in time, in order that the material saved there can be displaced into the disc margin 514 and/or can be used as material for the zones with material accumulation.
  • the zones 590 which form the balancing mass for the valve 562 to form further, for example strip-shaped or rib-shaped zones with material reduction or material accumulation, as has been described by way of example with regard to the preceding exemplary embodiments.
  • the vehicle wheel 650 has a wheel rim part 660 which is of substantially arbitrary form and which has a valve hole 663 for receiving a valve 662, and the wheel disc 610 produced by flow-forming is, by way of the disc margin 614 generated during the flow-forming process, connected rotationally conjointly to the wheel rim inner side of the wheel rim part 660 by means of weld seams (not illustrated in detail).
  • the valve 662 is positioned so as to lie centrally with respect to a ventilation hole 618 in the flow-formed transition surface 613 of the wheel disc 610.
  • a ventilation hole 618 which lies, in effect, in front of the valve 662, two relatively small, in this case recess-like zones 690 with material reduction are formed in the transition surface 613 on the inner side 616 of the wheel disc 610, which zones have been generated by means of corresponding elevations on the outer side of the side wall of the spinning mandrel during the flow-forming process.
  • said zones 690 with material reduction may be used for setting or centring the position of the wheel disc form before all of the ventilation holes 618 are punched out, in order that, after the punching of the ventilation holes 618, the two zones 690 lie exactly centrally between two ventilation holes 618.
  • the weight that is saved by way of the zones 690 is coordinated with the valve weight of the valve 662 and the distance thereof from the axis of rotation, in order to compensate for the imbalance of the vehicle wheel 650 caused by the valve 662.
  • the two zones 690 with depressions in the form of circular recesses as material reduction lie in the centre of the intermediate sections 624 between in each case two adjacent ventilation holes 618.
  • Figures 24 to 26 show an eighth exemplary embodiment, wherein these figures show a wheel disc form 770 as could be present at the end of the flow-forming step.
  • the attachment flange 712, the transition surface 713 and the disc margin 714 have duly already been formed on the wheel disc form 770, but neither bolt holes nor ventilation holes have been punched out.
  • the positions of the ventilation holes to be produced during the punching process (or for example laser-cutting process) is indicated, by way of the ventilation hole margin, in the figures by the line 788.
  • the flow-forming of the preform is performed against a spinning mandrel which has at least depressions for forming in each case four stud-like zones 765 with material accumulation on the inner side 716 of the transition surface 713 during the flow-forming step, wherein, as can be seen very clearly from the figures, said individual zones 765 are positioned such that a sub-region of each zone 765 lies outside the ventilation hole margin 788 and another sub-region of each zone 765 lies within the respective ventilation hole that has yet to be punched out.
  • a subsequent punching step or cutting step
  • zones 765 around the ventilation holes are positioned in relation to the central point or the radial plane E of each ventilation hole such that said zones have an angular spacing of 90° to one another and, in relation to the radial plane E through a ventilation hole, are each offset by 45° with respect to said radial plane.
  • the additional material required for the zones 765 with material accumulation can be removed in particular from the central region of the slug 771 which is removed during the punching process, and in which, correspondingly, a zone 772 with material reduction is correspondingly formed, said zone in this case again being circular. Since said slug 771 is removed in any case during the punching process, it can be thinned to any desired extent as long as a minimum thickness is not required for the material flow during the metal spinning or flow forming of the disc form 770. Instead of four stud-like zones, it would also be possible for only two stud-like zones with material accumulation to be provided, which preferably lie at the ventilation hole margin closest to the disc margin.
  • the disc margin is preferably provided with the contour that has been explained in detail with regard to Figures 2 to 6 .
  • Individual zones may be provided with different material reductions, and also different shapes, wherein preferably, identical shapes are formed so as to be distributed over the circumference.
EP15728148.6A 2014-04-15 2015-04-15 Method for producing wheel disc forms on flow-forming machines Active EP3131690B1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE102014105400.8A DE102014105400A1 (de) 2014-04-15 2014-04-15 Verfahren zum Herstellen von Radschüsselformen auf Drückwalzmaschinen, Fahrzeugrad mit einer solchen Radschüsselform und Drückfutter für Drückwalzmaschinen zum Herstellen entsprechender Radschüsselformen
PCT/IB2015/052742 WO2015159231A1 (en) 2014-04-15 2015-04-15 Method for producing wheel disc forms on flow-forming machines, vehicle wheel having a wheel disc form of said type, and spinning mandrel for flow-forming machines for producing corresponding wheel disc forms

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EP3131690A1 EP3131690A1 (en) 2017-02-22
EP3131690B1 true EP3131690B1 (en) 2022-08-17

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EP (1) EP3131690B1 (zh)
CN (1) CN106457340B (zh)
BR (1) BR112016017583B1 (zh)
DE (1) DE102014105400A1 (zh)
WO (1) WO2015159231A1 (zh)

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CN109145335B (zh) * 2017-06-28 2023-05-30 中国航发贵阳发动机设计研究所 一种通过预旋转提高轮盘低循环疲劳寿命的方法
CN113173034A (zh) 2021-06-10 2021-07-27 蒂森克虏伯钢铁(北京)有限公司 用于商用车辆的超轻量化钢制车轮
DE102022101406A1 (de) 2022-01-21 2023-07-27 Thyssenkrupp Steel Europe Ag Verfahren zur Herstellung einer Radschüssel für ein Fahrzeugrad
DE102022105159B4 (de) 2022-03-04 2023-09-28 Maxion Wheels Holding Gmbh Radschüssel für Fahrzeugräder, Verfahren zur Herstellung und Fahrzeugrad

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BR112016017583A2 (pt) 2017-08-08
DE102014105400A1 (de) 2015-10-15
EP3131690A1 (en) 2017-02-22
BR112016017583B1 (pt) 2021-10-13
WO2015159231A1 (en) 2015-10-22
CN106457340A (zh) 2017-02-22
CN106457340B (zh) 2020-05-29

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