JPH05200472A - Manufacture of wheel - Google Patents

Abstract

PURPOSE:To reduce working processes, to improve productivity and to enable the manufacture of a wheel, of which the annular ornamental part of a disk part is continued on the inner circumference of the outer rim, by integrally fabricating a rim part with the disk part a disk-shaped base stock provided with tapered cylinder part and a thick part, in the casting process before parting. CONSTITUTION:In the parting process, a thick part 12 is formed into an inner rim equivalent 11a and an outer rim equivalent 11b that is continued to the annular ornamental part of the disk part. It is parted within the range of a place that is equivalent to a drop center part positioned inside the circumference of the annular ornamental part in a completed condition; and the outer rim equivalent 11b that is positioned outside the disk in the valley part of the parting and the inner rim equivalent 11a in the tapered shape inside are formed. Consequently, most of the inner rim equivalent 11a is the tapered cylinder part 13 that is formed through casting, and the time required to form the inner rim equivalent 11a is shortened. Also, the inner rim equivalent 11a that is continued to the circumference of the disk part and the outer rim equivalent 11b are formed by a spinning process, and the wheel is thus completed.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method of manufacturing a wheel having a large disc offset amount, and more particularly to a wheel made of an aluminum alloy having a high malleability and in which a disc portion and a rim portion are integrated. The present invention relates to a method for manufacturing a wheel that is finished into a final shape by forging and spinning.

[0002]

2. Description of the Related Art As a method for manufacturing a wheel made of a material having high ductility by spinning, there is one already disclosed in Japanese Patent Publication No. 03-71209, which is shown in FIGS. The rim part (1) is manufactured by the process shown, and this rim part is attached to the mounting flange (10) as shown in FIG.
It is screwed to the peripheral edge of the disc part (2) as shown in.

In this type, as shown in FIG. 1, the outer peripheral portion of a disk-shaped material (M) having a uniform thickness and a large opening in the center is spread by spinning to the side corresponding to the inner rim. To form a thin-walled tubular portion, a step of radially cleaving the disk-shaped material (M) at the base end portion of the tubular portion, and one of the cleaving portions and the tubular portion Forming the rim (1a) and the outer rim (1b) by the other of the split portions. In the rim part (1) formed in this way,
The inner peripheral end of the disc-shaped material (M) serves as a mounting flange (10) protruding in a direction perpendicular to the rim (1). And
Attach the rim (1) to the mounting flange (10) as shown in FIG.
The wheel is completed by screwing to the periphery of the disc part (2) using.

In this wheel manufacturing method, the rim portion (1)
Since the disc part (2) and the disc part (2) are separate parts, they must be manufactured separately, and an assembly process is required.
Since the part corresponding to (1a) is expanded into a cylinder prior to the cleaving process, the mounting flange (10) for the rim (1) is
The advantage is that the offset amount can be increased. Therefore, if the central opening of the disc-shaped material (M) is set small and the disc-shaped material (M) itself is equipped with the disc portion (2), a wheel with a large offset amount can be integrated. Can be manufactured.

However, even if such a manufacturing method is adopted, the efficiency of the manufacturing is insufficient as long as the above-mentioned prior art is directly adopted as the manufacturing process of the rim portion (1). This is because a process of processing the cylindrical portion corresponding to the inner rim (1a) is required prior to the cleaving process, which requires a long time. In the case of the above-mentioned conventional method,
There is a problem that it is not possible to manufacture a wheel in which the annular decorative portion of the disc portion (2) is continuous on the inner peripheral side of the outer rim (1b).

The present invention has been made in view of the above points, and is made of an aluminum alloy in which the disc portion (2) and the rim portion (1) are integrated and the disc portion (2) has a large offset amount. A manufacturing method of a wheel, wherein the disc-shaped material (M) is cleaved and then the inner rim (1a) and the outer rim (1b) are processed by spinning. ”
In order to shorten the machining process and improve the productivity, it is possible to manufacture a wheel in which the annular decorative portion of the disc portion (2) is continuous on the inner peripheral side of the outer rim (1b). The task is to do.

[0007]

[Technical Means] A technical means of the present invention for solving the above-mentioned problem is to provide a "disk portion (2) having an annular decorative portion (22) on the outer periphery and a rim on the peripheral portion of the annular decorative portion (22). Corresponding part (11)
The plate-shaped disc-shaped material (M) formed so as to have a disc part is manufactured by forging.
The thick portion (12) following the peripheral portion of the annular decorative portion (22) of (2) and the disc portion (2) from the position deviated to the inner surface side of the disc portion (2) on the outer periphery of the thick portion (12). ) Of the disk part that protrudes toward the inner surface and expands toward the tip.
The mandrel (41) that contacts the periphery of the annular decoration part (22) on the outer surface of (2) and the inner peripheral side in the vicinity thereof and the mandrel that contacts the inner peripheral region of the rim equivalent part (11) on the inner surface of the disk part (2). The disc portion (2) is clamped by (42), and the thick portion (12) of the disc-shaped material (M) is pressed from the outer peripheral surface to the annular decorative portion (2
The outer rim-corresponding part (1) that is continuous with the outer periphery of the annular decoration part (22) by cleaving to the part corresponding to the drop center adjacent to the peripheral part of (2)
1b) and an inner rim equivalent part (11a) consisting of a tapered cylindrical part (13) and a part continuous with this, and this inner rim equivalent part (11a)
And the outer rim equivalent part (11b) is processed into the inner rim (1a) and the outer rim (1b) by spinning ”.

[0008]

The above technical means operates as follows. In the forging step before dehiscence, since the disc-shaped material (M) having the taper cylinder portion (13) and the thick wall portion (12) is manufactured integrally with the disc portion (2), the rim portion (1 Material loss is less than in the case of manufacturing only) by forging, and the wall thickness of the portion corresponding to the tapered cylindrical portion (13) is likely to be uniform.

In the cleaving process, the thick wall portion (12) is formed with an inner rim corresponding portion (11a) and an outer rim corresponding portion (11b) continuous with the annular decorative portion (22) of the disc portion (2). In the completed state, the disc-shaped material is cleaved and cleaved in a range up to a position corresponding to the drop center portion located inside the peripheral portion of the annular decorative portion (22) (inward in the disc axial direction). (M) is
The cleavage trough is located at a position corresponding to the diameter of the drop center (1c) of the rim.On the outer surface side of the disc of this cleavage trough, a cross section along the peripheral edge of the annular decoration (22) is formed. A portion and an outer rim corresponding portion (11b) located on the outer peripheral side thereof are formed, and a tapered inner rim corresponding portion (11a) is formed inside. At this time, since the outer mandrel (41) is in contact with the peripheral portion of the annular decoration portion (22), the deformation of the annular decoration portion (22) when the outer rim equivalent portion (11b) is formed by dehiscence. Can be prevented.

In the case of splitting as described above, most of the inner rim corresponding portion (11a) is a tapered cylindrical portion (13) formed by forging, and is formed only by spinning from a thick plate material. The time required to mold the inner rim corresponding part (11a) is shortened as compared with the case where the rim corresponding part (11a) is manufactured. Then, the inner rim equivalent part (11a) and the outer rim equivalent part (11b) following the periphery of the disc part (2) are processed into the inner rim (1a) and the outer rim (1b) by spinning, and the wheel is completed. .. At this time, the wall thickness of the portion corresponding to the inner rim (11a) is set to a predetermined wall thickness by the forging process, and the entire inner rim has a shape that expands toward the tip. Good spinning workability to finish the final cross-sectional shape of (1a).

[0011]

[Effect] Since the wheel is completed by the forging process, the splitting process, and the spinning process, the wheel manufacturing process is greatly rationalized and the production is improved as compared with the conventional one. Inner rim equivalent part (11a) prior to spinning
Since the forming step can be significantly shortened in time as compared with the case of forming only by the conventional spinning process, the productivity of the wheel is also improved in this respect.

By forging, the disk portion (2) and the tapered cylindrical portion (13), which is a large part of the inner rim equivalent portion (11a), are integrally formed, and the wall thickness accuracy of this portion is good, so The finishing accuracy of the rim (1a) and the spinnability of this portion are also good. Since the annular decorative part (22) is prevented from being deformed due to the cleavage, the circular decorative part (22) of the disc part (2) is cleaved to the drop center part on the inner surface side of the wheel. It is possible to manufacture a wheel in which an annular decorative portion is continuous on the inner peripheral side of the rim (1b).

[0013]

Embodiments of the present invention described above will now be described in detail with reference to the drawings. In this embodiment, a wheel having a cross-sectional shape shown in FIG. 5 is manufactured, and the disk portion (2) of this wheel is provided with various patterns and openings on the outer periphery of the central axle mounting portion (21). Is formed so that the outer rim (1b) of the rim portion (1) is continuous with the outer peripheral edge of the annular decoration portion (22), and the drop of the rim portion (1) is formed. The disc portion (2) is provided between the center (1c) and the outer rim (1b).
And the disc is largely offset to the outer surface of the wheel with respect to the rim (1).

The disc-shaped material (M) is manufactured by forging, and the entire disc portion (2) of this disc-shaped material (M) is finished in the final shape as shown in FIG. A fixed range from the peripheral edge of the disc portion (2) is the annular decoration portion (22). Depending on the case, the bolt holes and the like of the axle mounting portion (21) may be formed by post-processing. A thick part (1) is formed on the periphery of the disk part (2) formed as described above.
2) is continuously formed, in this embodiment, the cross section of the thick portion (12) is trapezoidal with a small width on the inner peripheral side and is continuous with the annular decorative portion (22). , The taper tube portion (13) in a manner to be uniformly continuous with the end surface (12a) on the inner surface side of the thick portion (12)
Are formed. As shown in FIG. 7, the annular decorative portion (22) has a large number of concave portions (22a) (22a) from the outer surface side of the disc portion (2).
The structure a) is continuous in the circumferential direction.

The tapered cylindrical portion (13) has a tapered shape that expands toward the tip, and its maximum outer diameter is set to be substantially equal to or slightly larger than the outer diameter of the wheel. Further, the wall thickness of the tapered cylindrical portion (13) is set to a predetermined value in relation to the thickness reduction rate in the subsequent spinning process, and the ear portion (14) of the inner rim (1a) in the final shape. If the wall thickness of the other parts is 3 mm, the wall thickness of this taper cylinder part (13) is set to about 10 mm, and the cross-section length that becomes the final rim cross-sectional shape is set by the ironing component of the spinning process. There is.

The thickness of the thick wall portion (12) is set to be slightly larger than about twice that of the taper cylinder portion (13), and the taper cylinder portion (13) has an inner surface thereof. Are extended so as to be continuous with the inner surface side end surface (12a) of the thick portion (12). As shown in FIG. 8, the disc-shaped material (M) formed in this manner is torn to a predetermined depth using a tear roller (31) at a position following the base end of the tapered cylindrical portion (13). Open. As a result, the outer part after dehiscence becomes the outer rim equivalent part (11b), and the outer part after dehiscence is continuous with the tapered cylindrical part (13) with a uniform thickness, and the whole part corresponds to the inner rim (11a). ).

In this cleaving process, the disk portion (2) is clamped by the mandrels (41) (42), but the disc-shaped material (M) formed as shown in FIGS. 6 and 7 is As shown in FIG. 8, the mandrel (42) that substantially matches the inner peripheral diameter of the inner rim equivalent portion (11a) and the outer peripheral diameter of the annular decorative portion (22) that substantially matches the surface of the annular decorative portion (22). The disc portion (2) is pinched by the mandrel (41) having an end face shape that matches the shape and the disc portion (2) is torn along the virtual tear line (30).

The virtual dehiscence line (30) is set so as to incline along the outer peripheral edge of the annular decoration (22) which is the bottom wall of the recess (22a). When dehiscing along the line (30), this dehiscence causes the bottom wall end (2) of the recess (22a).
A part of the cross section of the drop center (1c) adjacent to 2c) will be roughly formed. In addition, since the end face of the mandrel (41) is in contact with the portion adjacent to the cleavage valley at the edge of each recess (22a), the shape of the annular decorative portion (22) is distorted during the cleavage process. No worries.

In the annular material (M), if the angle of the outer peripheral surface of the taper cylinder portion (13) and the angle of the chevron peripheral portion of the cleaving roller (31) are set to a predetermined value, the thick wall portion The bending angle at the boundary between the inner portion of the portion where the (12) is cleaved and the tapered cylindrical portion (13) is extremely small. For example, the angle of the taper tube portion (13) with respect to the axis of the disc portion (2) is set to about 45 degrees, and the angle of the outer peripheral surface of the tear roller (31) is set to about 20 to 40 degrees. After the dehiscence,
a) has a substantially uniform taper shape. In this way, the fact that the inner rim equivalent part (11a) has a uniform taper shape
This is advantageous in the spinning process that follows.

The disc-shaped material (M) thus cleaved is clamped by mandrels (43) (44) as shown in FIG.
Following the rim cross-section formed on the outer peripheral surface of this mandrel, when the inner rim equivalent part (11a) and the outer rim equivalent part (11b) are spin-processed using the spinning roll (32), the inner rim (1a) and the outer rim (1a) A rim (1b) is formed. In this case, if the thickness reduction rate during the spinning process is set to about 70%, a good finish can be secured without causing large work hardening.

At this time, the wall thickness and the cross-sectional length of the inner rim corresponding portion (11a) are set to predetermined values in advance so as to fit the inner rim (1a) of the final shape. Rim equivalent part
Since the outer diameter of (11a) is set to be larger than the outer diameter of the wheel, the inner rim (1a) is formed by a combination of a very small drawing process and a predetermined ironing process.
It is possible to cold work to the final rim cross-sectional shape without cracking.

Although the dehiscence virtual line (30) is set obliquely in the above embodiment, the dehiscence virtual line (30) may be bent as shown in FIGS. 10 to 12. .. Figure 1
In the embodiment shown in FIG. 0, the outer rim equivalent part (11b) having a uniform cross section is cleaved so as to protrude from the bottom wall end (22c) of the concave part (22a) of the annular decoration part (22). , As in the above example,
The bottom wall end (22) and the drop center (1c) are continuous in the axial direction.

In this embodiment, as shown in FIG. 10, the thick-walled portion (12) of the disc-shaped material (M) has a thickness equal to that of the tapered cylindrical portion (13) and is equivalent to the outer rim portion ( 11b), and when this thick part (12) is torn open so that it bends at the edge of the bottom wall end (22c) as shown in FIG. 11, the inner rim equivalent part (11
Both a) and the outer rim equivalent part (11b) have uniform thickness.
Then, when the rim-corresponding portions thus split apart are finished into a final shape by spinning, a wheel as shown in FIG. 12 is obtained.

It is desirable that the portion (11a) corresponding to the inner rim after dehiscence has a uniform taper shape. For this purpose, the taper angle of the disc material (M) and the dehiscence roller ( The apex angle and the tearing direction of 31) may be set to predetermined conditions. At this time, if the angle of the virtual dehiscence line (30) with respect to the plane perpendicular to the wheel axis is θ, this angle should match the angle of the outer slope of the drop center (1c) of the completed rim cross section. The sloping surface will be formed by the cleavage. Further, in this way, when obliquely cleaving, the angle of the outer tapered surface (31a) of the triangular cross-section of the peripheral edge of the cleaving roller (31) is equal to or the same as the virtual virtual cleaving angle θ. Than 5 degrees to 1
When the clearance angle is set by setting it to be small by 0 degree, the tearing process proceeds smoothly. On the other hand, the angle of the taper surface (31b) inside the peripheral edge of the cleaving roller (31) may be set to about 25 ° to 45 °, and the arc of the peripheral edge of the cleaving roller (31) is The radius is preferably about 1 mm to 5 mm. (See Figure 8)
Further, the slope portion outside the drop center (1c) is set to 15 to 30 degrees, so if the above-mentioned virtual rupture line angle θ is set to this value, this portion will be ruptured. By the opening process, the final shape is almost finished.

Further, normally, in order to promote the air cooling effect of the brake device portion, the annular decoration portion (22) is provided with the disc portion (2).
Often, an opening is formed that communicates with the inside and outside of the. For this purpose, the disc-shaped material (M) should be formed by forging so as to have the opening (H) shown in FIGS. 6 and 7 in a predetermined area of the bottom wall of the recess (22a). Alternatively, the opening (H) is formed in the predetermined range after the forging process or after the completion.

[Brief description of drawings]

FIG. 1 is an explanatory diagram of a first step of a conventional example.

FIG. 2 is an explanatory view of the dehiscence process.

FIG. 3 is an explanatory diagram of a spinning process for this.

FIG. 4 is an explanatory view of a conventional wheel.

FIG. 5 is a sectional view of a wheel manufactured by the method of the present invention.

[Fig. 6] Sectional view of disk-shaped material (M)

[Fig. 7] Front view of disk-shaped material (M)

FIG. 8 is an explanatory diagram of the dehiscence process.

FIG. 9 is an explanatory diagram of a spinning process step.

FIG. 10 is an explanatory diagram of a disc-shaped material (M) according to another embodiment of the method.

FIG. 11 is an explanatory diagram of the dehiscence process in this case.

FIG. 12 is a sectional view of the final finished shape in the case of this embodiment.

[Explanation of symbols]

 (2) ・ ・ ・ Disc part (1) ・ ・ ・ Rim part (M) ・ ・ ・ Disc-shaped material (1a) ・ ・ ・ Inner rim (1b) ・ ・ ・ Outer rim (11) ・ ・ ・ Rim equivalent Part (12) ・ ・ ・ Thick part (13) ・ ・ ・ Taper cylinder

Claims (1)

[Claims] 1. A method of manufacturing a wheel made of an aluminum alloy in which a disc portion (2) and a rim portion (1) are integrated and a large offset amount of the disc portion (2) is provided, which is a disc-shaped material.
In the method for manufacturing a wheel in which the inner rim (1a) and the outer rim (1b) are processed by spinning after cleaving (M), a disk part (2) provided with an annular decorative part (22) on the outer circumference is provided. ) And the rim-corresponding part (1
The plate-shaped disc-shaped material (M) integrally formed with 1) is manufactured by forging, and the rim-corresponding part (11) has a thickness continuing from the peripheral part of the annular decorative part (22) of the disc part (2). Meat part (12) and this thick part
The disk portion (12) is formed on the outer periphery of the outer peripheral surface of (12) and is tapered toward the inner surface side of the disk portion (2) from a position biased toward the inner surface side of the disk portion (2) and expands toward the tip. 2) The inner surface of the mandrel (41) and the disk portion (2) that are in contact with the peripheral edge of the annular decorative portion (22) on the outer surface of the outer peripheral surface of (2) and in the vicinity of the inner peripheral side of the annular peripheral portion (22).
The disk part (2) is pinched by the mandrel (42) facing the inner peripheral area of (1), and the thick part (12) of the disc-shaped material (M) is annularly pressed from its outer peripheral surface in this pinched state. An outer rim equivalent part (11b) continuous with the outer periphery of the annular decorative part (22) by cleaving to a drop center equivalent part adjacent to the peripheral part of the decorative part (22), and a tapered tubular part (13) It is divided into an inner rim equivalent part (11a) consisting of continuous parts, and this inner rim equivalent part (11a) and outer rim equivalent part (11b) are processed into an inner rim (1a) and an outer rim (1b) by spinning. A method of manufacturing a wheel adapted to be molded.