JP2001088504A - Two-piece aluminum alloy wheel for automobile and manufacturing method thereof - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a two-piece aluminum alloy wheel for an automobile and a manufacturing method thereof reducing the number of processes required and reducing the weight of the whole wheel. SOLUTION: This wheel has a rim 1 formed of an aluminum alloy extruded shape of the same across-sectional shape as rim cross-sectional shape, and a disc 2 made to the aluminum alloy and fitted and welded to the opening part of the rim 1. The wheel is manufactured by forming the aluminum alloy extruded shape of the same cross-sectional shape as the rim cross-sectional shape into cylindrical shape, jointing both edges to form the rim 1, then fitting the disc 2 made of the aluminum alloy, into the opening part of the obtained rim 1, and welding the contact corner parts between the inner peripheral surface of the rim 1 and the disc 2.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a two-piece aluminum alloy wheel for automobiles comprising a plurality of members and a method of manufacturing the same.

[0002]

2. Description of the Related Art Conventionally, there has been known an aluminum alloy wheel comprising a plurality of members having a rim and a disk used in an automobile or the like (JP-A-4-321401). 16 is a cross-sectional view showing a conventional first two-piece aluminum alloy wheel, FIG. 17 is a cross-sectional view showing a conventional second two-piece aluminum alloy wheel described in the above publication, and FIG. 18 is a conventional rim. FIG. 19 is a sectional view showing a third conventional two-piece aluminum alloy wheel.

As shown in FIG. 16, a conventional first two-piece aluminum alloy wheel is formed by rolling a rolled aluminum alloy plate having a uniform thickness and subjecting the end face to a wide ring by flash butt welding to form a wide ring. A plate rim 100 formed into a rim shape by molding;
And a disk 101 manufactured by forging or casting, which is joined after fitting into the narrowest diameter portion of the opening of No. 0.

[0004] In the conventional second two-piece aluminum alloy wheel shown in FIG.
02 has a flange 104 on the front side, and a bosh-shaped fitting surface 105 is formed on the inner side of the flange 104. Also, the front side flange 106 of the disc 103
Is formed with a bosh-shaped second fitting surface 107 that is closely fitted to the bosh-shaped fitting surface 105. Then, the fitting surfaces 105 and 107 are brought into close contact with each other to make the plate rim 102
A wheel is manufactured by fitting a disk 103 to the rim and welding.

In the conventional two-piece aluminum alloy wheel shown in FIGS.
02 as the structural tolerance allowable cross section required for the plate rim 1
02 can be made thinner. However, since the roll processing of the plate uses a rolled plate having a constant plate thickness, the conventional two-piece aluminum alloy wheel is
As shown in FIG. 18, the wall thickness becomes constant and the plate rim 102
There is a problem in that the central portion is unnecessarily thick and the weight cannot be reduced accordingly.

Therefore, in order to reduce the weight of the roll rim of a plate, a third conventional two-piece aluminum alloy wheel shown in FIG. 19 has been proposed. This is disk 1
The thickness of the central portion of the rim 112 is reduced by performing spinning processing on the central region 113 of the rim 112 in which 11 is fitted.

[0007]

However, the above-mentioned conventional third two-piece aluminum alloy wheel has problems that the cost for spinning increases and the number of steps increases.

Further, there is a problem that a cast disk manufactured by casting has a lower strength than a forged disk manufactured by forging, and there is a limit in weight reduction by thinning.

SUMMARY OF THE INVENTION The present invention has been made in view of the above problems, and provides a two-piece aluminum alloy wheel for an automobile which can be reduced in weight as a whole and has a small number of steps, and a method of manufacturing the same. With the goal.

[0010]

SUMMARY OF THE INVENTION According to the present invention, there is provided a motor vehicle.
The piece aluminum alloy wheel includes a rim formed by an extruded material made of an aluminum alloy having the same cross-sectional shape as the rim cross-section, and a disk made of an aluminum alloy fitted and welded to the opening of the rim. It is characterized by having.

In the present invention, the rim is formed of an extruded member made of an aluminum alloy, and the extruded member can have any cross section perpendicular to the extrusion direction. When the rim is formed from the extruded die so that the shape matches the cross-sectional shape of the extruded die, the cross-sectional shape of the rim can be arbitrarily set. Thereby, the cross-sectional shape of the rim can be optimized so that the central portion thereof is thin. For this reason, weight reduction can be achieved while satisfying the strength of the whole wheel.

It is preferable that the disk is a forged product. As a result, the disk can be made thinner to obtain the same strength as that of a cast product, so that the weight of the entire wheel can be further reduced.

According to the method for manufacturing a two-piece aluminum alloy wheel for an automobile according to the present invention, a rim is formed by molding an extruded material made of an aluminum alloy having the same cross-sectional shape as a rim into a cylindrical shape and joining both end edges thereof. And a step of fitting a disk made of an aluminum alloy into the opening of the obtained rim, and welding and joining a corner formed by the inner peripheral surface of the rim and the disk.

In the present invention, the wheel is formed by molding an extruded member made of an aluminum alloy into a cylindrical shape, fitting a disk made of an aluminum alloy into an opening portion and welding the same, and the extruded member is perpendicular to the extrusion direction. Since the shape of the cross-section can be set arbitrarily, if the rim is formed from the extruded material so that the cross-sectional shape of the surface including the wheel axis of the rim coincides with the cross-sectional shape of the extruded material, the rim cross-sectional shape can be arbitrarily set. Can be. As a result, the cross-sectional shape of the rim can be optimized by making the central portion thinner, so that the weight can be reduced while satisfying the strength of the entire wheel.

Further, since an extruded die made of an aluminum alloy having the same cross-sectional shape as the rim cross-sectional shape is used, the number of steps can be reduced and the cost can be reduced.

[0016]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, a two-piece aluminum alloy wheel according to an embodiment of the present invention will be described in detail with reference to the accompanying drawings.

FIG. 1A is a front view showing a two-piece aluminum alloy wheel according to an embodiment of the present invention.
FIG. 2B is a cross-sectional view taken along line AOA, and FIG. 2 is a cross-sectional view showing the rim.

In this embodiment, FIGS. 1 (a) and 1 (b)
As shown in the figure, the rim 1 is formed by molding an extruded material made of an aluminum alloy into a cylindrical shape so that the extruding direction is a circumferential direction, and joining both ends of the extruded shape material formed into a cylindrical shape. A rim 1 is obtained, and a disc 2 made of an aluminum alloy is fitted into one opening of the rim 1.

That is, FIG. 2 shows the cross-sectional shape (cross section) of a surface passing through the wheel axis of the rim 1, which is also a cross-sectional shape of a surface orthogonal to the extrusion direction of the extruded material.
By extruding the aluminum alloy material using such an extrusion die, as shown in FIG. 2, the central portion of the extruded profile, that is, the central portion in the cross section of the rim 1 has a small thickness. The rim 1 can be manufactured without spinning.

The disk 2 is a forged material of an aluminum alloy, and is fitted into one opening of the rim 1 as shown in FIG. 1 (b). Are welded.

In the present embodiment, the cross-sectional shape of the rim 1 is a cross-sectional shape in a cross section perpendicular to the extrusion direction of the extruded profile, and the cross-sectional shape of the rim 1 can be arbitrarily changed by changing the shape of the extrusion die. Can be set to Therefore, the cross-sectional shape of the rim 1 can be determined from the structural allowable cross section, and as shown in FIG. Thus, the weight can be reduced. Thereby, the weight can be reduced while satisfying the strength.

The forged material has high strength and high toughness and high reliability compared to the cast material.
By using a forged material, it is possible to reduce the thickness and weight with the same strength as compared with a cast material. In addition, a forged disc has a higher degree of freedom in shape, a better design, and a higher fashionability than a rolled material. Therefore, it is preferable to form the disk 2 by forging an aluminum alloy material.

Next, a method of manufacturing the aluminum alloy wheel according to this embodiment will be described. 3 to 15
FIG. 3 is a schematic view showing a method for manufacturing a two-piece aluminum alloy wheel according to an embodiment of the present invention in the order of steps. First,
For example, an Al-Mg-Si-based aluminum alloy is melted, and an ingot is manufactured by a semi-continuous casting method. After the ingot is subjected to the homogenizing heat treatment, as shown in FIG. 3, it is extruded to form an extruded die 3 having the same cross-sectional shape as the rim in cross section perpendicular to the extrusion direction.

Next, as shown in FIG.
Is cut into a predetermined length determined by the peripheral length of the rim to obtain the base material 4. Next, as shown in FIG. 5, the base material 4 is formed into a cylindrical shape by bending in a longitudinal direction by a roll forming process. Therefore,
The extrusion direction is the circumferential direction of the cylinder. Next, as shown in FIG. 6, the end face of the base material 4 is cut by a dedicated press.

Next, as shown in FIG.
Is flattened and the end faces are butted against each other. Next, as shown in FIG. 8, the butted portions are joined by flash butt welding. A burr 7 is formed at the joint 5, and the burr 7 at the joint 5 is removed as shown in FIG. 9. Next, as shown in FIG. 10, after the joint portion 5 is corrected into an arc shape, as shown in FIG. 11, the entire base material 4 is corrected into a predetermined shape. Next, the cross-sectional shape of the base material 4 having the shape shown in FIG.
By the finishing roll, the rim 1 is completed by finishing into a final shape as shown in FIG. The joining of the butted portions is not limited to the flash butt welding, but may be another joining method such as a friction stir welding method (FSW).

Next, as shown in FIG. 14, a disc 2 formed by forging an Al-Mg-Si based aluminum alloy, for example, is fitted into the opening of the rim 1. Next, as shown in FIG. 15, the disc 2 and the rim 1 are joined at a portion where both of the fitting portions are in contact with each other to form a joining portion 8.
Thereafter, a predetermined heat treatment (quenching or tempering) is performed, and finally, a surface treatment is performed to obtain a finished wheel product.

In this embodiment, the rim 1 is obtained by using the extruded die 3 having an arbitrary cross-sectional shape, and the rim 1 is formed by roll bending as in the case of manufacturing the rim 1 from a conventional rolled plate.
Since it is formed into a cylindrical shape, and a forged disc is fitted and welded and joined, a wheel having a rim 1 having an arbitrary cross-sectional shape is used.
It is possible to manufacture a wheel with reduced strength and weight by effectively reducing the thickness of unnecessary parts without providing a step having a high processing cost such as spinning.

Therefore, for example, while the weight of a wheel manufactured by the conventional manufacturing method is 4.8 kg, when a wheel having the same shape is manufactured by the manufacturing method of the present embodiment, the weight becomes 3. 2 kg, about 3
A weight reduction of 0% could be achieved.

This is because, in this embodiment, the extruded material 3
Since the rim 1 is molded from the rim 1, the cross-sectional shape of the rim 1 can be set arbitrarily, so that the cross-sectional thickness is not constant as in the conventional plate rim, and the strength required for the structure of the rim 1 This is because a cross section can be formed.

Further, in this embodiment, since it is not necessary to perform thin-wall processing such as spinning, the number of steps can be reduced, and therefore, the manufacturing cost can be reduced.

The disc 2 can be formed by casting. In this embodiment, the aluminum alloy for the rim 1 and the disk is Al-Si-Mg.
Aluminum alloy was used, but not limited to this.
An IS 6000 series aluminum alloy or the like can be used. Specifically, JIS 6151 alloy can be used.

[0032]

As described above in detail, according to the present invention, the rim is formed of an extruded member made of an aluminum alloy, and the extruded member can have any cross section perpendicular to the extrusion direction. When the rim is formed from the extruded material so that the cross-sectional shape of the surface including the wheel axis of the rim coincides with the cross-sectional shape of the extruded material, the cross-sectional shape of the rim can be arbitrarily set. Thereby, the cross-sectional shape of the rim can be made thin at the central portion, sufficient in strength, and optimized for weight reduction. For this reason, weight reduction can be achieved while satisfying the strength of the whole wheel.

According to the manufacturing method of the present invention, the wheel is assembled by forming an extruded material made of an aluminum alloy into a cylindrical shape, fitting a disk made of an aluminum alloy into an opening, and welding and joining the disk. Thus, a wheel having the above-described optimum cross-sectional shape can be manufactured at low cost without spinning.

[Brief description of the drawings]

FIG. 1A is a front view showing a two-piece aluminum alloy wheel according to an embodiment of the present invention, and FIG.
It is sectional drawing by the A line.

FIG. 2 is a cross-sectional view illustrating a cross-sectional shape of the rim according to the embodiment.

FIG. 3 is a schematic view illustrating a method for manufacturing a two-piece aluminum alloy wheel according to the present embodiment.

FIG. 4 is a schematic view showing a step subsequent to FIG. 3;

FIG. 5 is a schematic view showing the next step of FIG.

FIG. 6 is a schematic view showing a step subsequent to FIG. 5;

FIG. 7 is a schematic view showing a step subsequent to FIG. 6;

FIG. 8 is a schematic view showing the next step of FIG. 7;

FIG. 9 is a schematic view showing the next step of FIG.

FIG. 10 is a schematic view showing the next step of FIG. 9;

FIG. 11 is a schematic view showing the next step of FIG.

FIG. 12 is a schematic view showing a step subsequent to FIG. 11;

FIG. 13 is a schematic view showing the next step of FIG. 12.

FIG. 14 is a schematic view showing a step subsequent to FIG.

FIG. 15 is a schematic view showing a step subsequent to FIG. 14;

FIG. 16 is a sectional view showing a first conventional two-piece aluminum alloy wheel.

FIG. 17 is a sectional view showing a second conventional two-piece aluminum alloy wheel.

FIG. 18 is a sectional view showing an example of a sectional shape of a rim of the aluminum alloy wheel.

FIG. 19 is a cross-sectional view showing a third conventional two-piece aluminum alloy wheel.

[Explanation of symbols]

 1, 112; Rim 2, 101, 103, 111; Disk 3; Extruded material 4; Substrate 5; Joint 6, 8; End 7; Burr 100, 102; Plate rim 104; Flange 106; 107; fitting surface 113; area

Claims (3)

[Claims] 1. A rim formed by an extruded die made of an aluminum alloy having the same cross-sectional shape as the rim, and a disk made of an aluminum alloy fitted and welded to an opening of the rim. A two-piece aluminum alloy wheel for automobiles. 2. The two-piece aluminum alloy wheel for an automobile according to claim 1, wherein the disk is a forged product. 3. A step of forming an extruded die made of an aluminum alloy having the same cross-sectional shape as the rim cross-sectional shape into a cylindrical shape and joining both edges thereof to form a rim, and forming an opening of the obtained rim from an aluminum alloy. And welding the corner portion formed by the inner peripheral surface of the rim and the disc to form a two-piece aluminum alloy wheel for a vehicle.