US20070044311A1 - Method for manufacturing wheels - Google Patents

Method for manufacturing wheels Download PDF

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Publication number
US20070044311A1
US20070044311A1 US11/512,329 US51232906A US2007044311A1 US 20070044311 A1 US20070044311 A1 US 20070044311A1 US 51232906 A US51232906 A US 51232906A US 2007044311 A1 US2007044311 A1 US 2007044311A1
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United States
Prior art keywords
rim
plating
wheel
welding planned
welding
Prior art date
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Abandoned
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US11/512,329
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English (en)
Inventor
Takeshi Tanaka
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Work Co Ltd
Original Assignee
Work Co Ltd
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Assigned to WORK CO., LTD. reassignment WORK CO., LTD. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: TANAKA, TAKESHI
Publication of US20070044311A1 publication Critical patent/US20070044311A1/en
Priority to US12/929,300 priority Critical patent/US20110107599A1/en
Abandoned legal-status Critical Current

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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
    • B21D53/00—Making other particular articles
    • B21D53/26—Making other particular articles wheels or the like
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49481—Wheel making
    • Y10T29/49492—Land wheel
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49481—Wheel making
    • Y10T29/49492—Land wheel
    • Y10T29/49496—Disc type wheel
    • Y10T29/49497—Assembling wheel disc to rim and hub
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49481—Wheel making
    • Y10T29/49492—Land wheel
    • Y10T29/49496—Disc type wheel
    • Y10T29/49499—Assembling wheel disc to rim

Definitions

  • the present invention relates to a method for manufacturing wheels.
  • wheels for vehicles made of aluminum alloys and other light alloys include one-piece wheels integrally formed by welding, two-piece wheels configured by dividing the wheel into two parts that are a rim and a disk, and three-piece wheels configured by dividing the wheel into three parts that are an inner rim, an outer rim, and a disk.
  • a manufacturing method of two-piece wheels there is a widely adopted manufacturing method in which a cylindrical rim is heated to fit a disk in the inside of which a disk is fitted, and in a state that the disk is fitted and fixed to a suitable place in the axial direction of the rim by shrinkage-fitting, an outer circumferential surface of the disk is welded to an inner circumferential surface of the rim in order to integrate the disk and the rim into one.
  • a wheel subjected to a plating treatment such as chromium plating to enhance design features is proposed and put into practical use.
  • a whole wheel is immersed into plating liquid to carry out a plating treatment (for example, refer to Japanese Unexamined Patent Publication No. Hei 11-236681).
  • a plating treatment for example, refer to Japanese Unexamined Patent Publication No. Hei 11-236681.
  • two-piece wheels and three-piece wheels presence of plating at a welding planned portion of each of the wheel component members generates welding defects, and the following plating treatment is therefore implemented.
  • a welding planned portion is formed in at a halfway of an inner circumferential surface of a rim in the axial direction, causing it extremely troublesome to remove plating of the welding planned portion. Therefore, a wheel is generally configured to to provide a plating treatment only for a disk, not for a rim. Consequently, it is possible to fabricate a two-piece wheel in which a plating treatment is provided for a rim, but a plating treatment is not provided for a rim of a widely used wheel due to an increased manufacturing cost.
  • a plating treatment is provided for a disk and an outer rim, while for the inner rim having little effects on design features, an alumite treatment is provided in place of the plating treatment to reduce a manufacturing cost.
  • the outer rim is immersed in plating liquid to carry out plating treatment in a state of, for example, providing masking for a welding planned portion, or plating of the welding planned portion of the outer rim which have been subjected to a plating treatment is removed manually by the use of a portable grinder or the like, or plating of the welding planned portion of the outer rim is removed by cutting in a machine process, and with respect to the inner rim, oxide film of the welding planned portion is removed manually by the use of, for example, a wire brush or the like.
  • plating treatment requires special technique and it is not generally carried out by a wheel manufacturer but by a manufacturer specialized in a plating treatment, there is a problem of increasing a labor cost for a plating treatment for an operation of affixing a masking tape and increasing the a wheel manufacturing cost.
  • the plating liquid may invade between the masking tape and the rim when the rim is immersed in plating liquid and part of the welding planned portion may be plated, which is made to be one of the causes in welding defects of the plating part in the welding planned portion.
  • chromium plating is provided as a plating treatment
  • a rim is successively immersed in a plurality of treatment liquid, the plating liquid that invaded between a masking tape and the rim is brought into the other treatment liquid in the subsequent processes, creating a problem of contaminating treatment solutions in the subsequent processes.
  • an adhesive component of a masking tape is dissolved into treatment liquid, resulting in a problem of degrading treatment liquid.
  • plating of a welding planned portion is removed by cutting or the like in a machine process
  • plating of the welding planned portion can be neatly removed and an operation of affixing masking tape is not required, besides affixing a masking tape is not necessary, thereby a labor cost of plating treatment is minimized, the manufacturing cost of a wheel can be reduced.
  • cutting a plated area by a single cutting treatment causes a force exerted to the plated area in the direction to exfoliate plating when a cutting tool is withdrawn from the plated area, resulting in a problem of easy exfoliation of the plated area from the boundary with a base material portion.
  • processing carried out from an outer circumference side of an outer rim enables removal of plating with a comparative easiness even at a curved welding planned portion, but there are problems of requiring workforce and generating variations in dimensional accuracies and surface properties of a grinding surface.
  • a first manufacturing method of wheels related to the present invention includes steps of providing a chromium plating treatment to wheel component members, grinding a welding planned portion of the wheel component members by an abrasive cloth/paper, removing plating of the welding planned portion, and welding and joining the wheel component members along the welding planned portion.
  • a second manufacturing method of wheels related to the present invention is a manufacturing method of two-piece type wheels composed of a rim and ad disk, in which after providing a chromium plating treatment to a rim as a wheel component member, a welding planned portion with a disk on an inner circumferential surface of the rim is ground by an abrasive cloth/paper, removing plating of the welding planned portion, after which the disk is fixed into the rim, so that the disk and the rim are welded and joined along the welding planned portion.
  • a preferable embodiment includes steps such as using a grinding belt in which one end of the abrasive cloth/paper is stretched over a pulley capable of being inserted in the wheel and rotatable around a center axis thereof substantially parallel to a center axis of the wheel and the other end of the abrasive cloth/paper is stretched over a pulley rotatable around a vertical center axis thereof arranged outside of the wheel, and grinding with the abrasive cloth/paper pressed and brought in contact with the inner circumferential surface on a bottom of the rim under a condition that the rim is set with a center axis thereof made substantially in parallel to the support roller onto two parallel support rollers with center axes thereof made substantially horizontal at the grinding of inner circumferential of the rim.
  • a third manufacturing method of wheels related to the present invention is a manufacturing method of three-piece type wheels composed of an inner rim, an outer rim, and a disk, in which a chromium plating treatment is first provided for the outer rim as a wheel component member, then grinding a welding planned portion on an outer circumferential surface of the curved part linked from a superimposed part of rims to cylindrical body part in the outer rim using an abrasive cloth/paper, removing plating of the welding planned portion, superimposing a superimposed part to assemble both of the rims, superimposing an outer circumferential part of the disk to the superimposed part, after which the disk is fixed to the superimposed part by bolts, so that the welding planned portions of both of the rims are welded and joined from an outside.
  • a configuration of a preferable embodiment is to use a flap wheel with an abrasive cloth arranged radially as the abrasive cloth/paper to grind the welding planned portion by pressing and bringing the flap wheel substantially vertically in contact with a center part of the welding planned portion.
  • a welding planned portion is ground by an abrasive cloth/paper, it is made possible to neatly and accurately remove chromium plating or the like that is hard.
  • an operation of affixing a masking tape is not required, thereby labor cost for a plating treatment can be minimized and a wheel manufacturing cost can be reduced.
  • plating of a welding planned portion can be neatly removed by grinding, welding defects can be effectively prevented and stability in a wheel quality can be improved.
  • plating of a welding planned portion on an inner circumferential surfaces of the rims of a two-piece wheel can be removed, thereby an two-piece wheel which has plated rims can be fabricated easily and at low cost.
  • the use of a grinding belt as the abrasive cloth/paper enables to improve durability thereof, and a grinding operation can be efficiently carried out.
  • a side edge part of the grinding belt pressed and brought in contact with an inner circumferential surface of a rim is bent during grinding, thereby a welding planned portion from which plating was removed and a plated area can be formed into a smooth surface without having a level difference and exfoliation of plating at the boundary can be effectively prevented.
  • a rim onto two parallel support rollers with center axes thereof made substantially horizontal and grinding an inner circumferential surface on a bottom part of a rim by an abrasive cloth/paper enable to grind an inner circumferential surface of the rim at substantially the same height even if plating of a different seized rim is removed, and there is no need to adjust a height position of a abrasive cloth/paper for every change of the rim size, it is therefore possible to adopt a grinding device with a simple configuration.
  • plating of a welding planned portion of an outer rim can be removed, thereby it is made possible to fabricate three-piece wheels with a plated outer rim easily and at low cost. Furthermore, since a welding planned portion at a superimposed part has a cross-sectional profile protruding outwards, it is made possible to form a smooth surface between a welding planned portion from which plating was removed and a plated area without having a level difference, and as compared to cases of masking or cutting, exfoliation of plating at a boundary area can be effectively prevented.
  • the welding planned portion can be ground while an outer circumferential part of the flap wheel is being bent along a curvature of the welding planned portion; a required width of the welding planned portion can be neatly ground by a single grinding treatment and it is made possible to form a smooth surface between a welding planned portion and a plated part without a level difference while preventing the welding planned portion from being excessively ground, so that exfoliation of plating at the boundary can be effectively prevented further more.
  • a grinding treatment can be carried out with the same flap wheel and the operability of grinding treatment can be improved.
  • FIG. 1 is a front view of a two-piece wheel
  • FIG. 2 is a cross-sectional view taken along a line II-II of FIG. 1 ;
  • FIG. 3 is a view explaining a wheel manufacturing process
  • FIG. 4 ( a ) and FIG. 4 ( b ) are views explaining a press process and FIG. 4 ( c ) and FIG. 4 ( d ) are views explaining machining process;
  • FIG. 5 is a view explaining a spinning process
  • FIG. 6 is a view explaining a plating removing apparatus
  • FIG. 7 shows an operating state of a plating removing apparatus
  • FIG. 7 ( a ) is a view explaining a state of a rim placed on support rollers
  • FIG. 7 ( b ) is a view explaining a state of the rim held by holding rollers
  • FIG. 7 ( c ) is a view explaining a state immediately before a grinding belt is inserted to the rim;
  • FIG. 8 is a view explaining an operating condition of a plating removing means
  • FIG. 8 ( a ) is a view explaining a state of a grinding belt inserted to a rim
  • FIG. 8 ( b ) is a view explaining a state when a welding planned place is ground by the grinding belt
  • FIG. 8 ( c ) is a view explaining that a valve fixing hole is formed by a drill
  • FIG. 9 is a view explaining a ground portion by the grinding belt.
  • FIG. 10 is a cross-sectional view of a three-piece wheel
  • FIG. 11 is a view showing an operating condition of a plating removing apparatus
  • FIG. 11 ( a ) is a view explaining a rim set to a supporting means
  • FIG. 11 ( b ) is a view explaining a state of the rim held by holding rollers;
  • FIG. 12 is a view explaining an operating state of a plating removing apparatus
  • FIG. 12 ( a ) is a view explaining a state immediately before a welding planned portion of the rim is ground by a grinding means
  • FIG. 12 ( b ) is a view explaining a state of the welding planned portion of the rim ground with the grinding means:
  • FIG. 13 is a view explaining a grinding operation by abrasive cloth/paper
  • FIG. 14 is a view explaining a portion to be ground.
  • FIG. 15 is a view explaining a portion to be ground by masking related to a conventional technique.
  • the two-piece wheel 1 is equipped with a substantially cylindrical rim 2 and a disk 3 fitted into and fixed to a inside the rim 2 , in which the two-piece wheel 1 is assembled by welding an outer circumferential part of the disk 3 to be joined to an inner circumferential surface of the rim 2 in a state that the disk 3 is fitted and fixed to the rim 2 by shrink-fitting.
  • the disk 3 is integrally formed using aluminum alloys and other lightweight metal material by casting, press-forming, and forging or the like, and equipped with a fixing part 4 to a wheel support member (illustration omitted), an annular ring part 5 installed in such a manner as to surround and enclose the fixing part 4 and a spoke part 6 that joins the fixing part 4 to the ring part 5 , in which a whole surface thereof is subjected to a chromium-plating treatment.
  • the plating treatment is carried out by a widely known method to immerse the rim 2 in plating liquid, and plating of a welding planned portion DW of the disk 3 with respect to the rim 2 is removed by masking or grinding.
  • the rim 2 is composed with metal material with superb stretchability such as aluminum alloys, and a whole surface thereof is subjected to a treatment such as chromium plating.
  • the plating treatment is carried out by a widely known method to immerse the rim 2 in plating liquid and plating of a welding planned portion RW of the rim 2 with respect to the disk 3 is removed in grinding by a plating removing apparatus 20 discussed below.
  • flange parts 7 are formed with a wall thicker than other parts by increasing a wall thickness. Because the flange part 7 is configured to be thick by increasing the wall thickness in this way, when the rim 2 is subjected to a plating treatment, plating liquid or the like is securely prevented from remaining inside the flange part 7 and corrosion of the flange part 7 caused by the remaining plating liquid can be prevented. In addition, because the flange part 7 is configured to have a thick wall, strength and rigidity of the wheel 1 can be sufficiently secured during rotation or the like.
  • the manufacturing method of this wheel 1 is composed of, as shown in FIG. 3 , a rim manufacturing process for manufacturing the rim 2 , a disk manufacturing process for manufacturing the disk 3 , a plating treatment process for providing chromium plating to the rim 2 and the disk 3 , a plating removing process for removing plating of welding planned portions RW and DW between the rim 2 and the disk 3 , and an assembly process for assembling the wheel 1 from the rim 2 and the disk 3 . Because the present invention is characterized by a configuration of easily and neatly removing plating of the welding planned portion RW on the inner circumferential surface of a rim 2 , processes other than the plating removing process of the rim 2 will be briefly explained.
  • a disk-form rolled metal plate 10 with superb stretchability such as aluminum alloy is press-formed as shown in FIG. 4 ( a ), so as to fabricate a primary forming 13 having a cylindrical tubular part 11 with a bottom 14 and a flange part 12 that extends outwards from an end part of an opening side of the tubular part 11 as shown in FIG. 4 ( b ), after which a primary forming 13 A is fabricated by removing the bottom part 14 of the primary forming 13 by punching processing or the like as shown in FIG.
  • a flange part 15 is formed next by press-forming an opening end part of the primary forming 13 A from which the bottom 14 was removed, so as to fabricate a secondary forming 16 with flange parts 12 and 15 formed on both ends of the tubular part 11 as shown in FIG. 4 ( d ).
  • the manufacturing method of the secondary forming 16 can be provided in such a manner that a slender rolled metal sheet with outstanding stretchability such as aluminum alloy is rolled in a cylindrical form and both end parts are welded to fabricate a tubular member, in which both end parts of this tubular member is subjected to press-forming to form flange parts.
  • the secondary forming 16 is externally fitted to be fixed to a mandrel 17 , and while the secondary forming 16 is being rotated together with the mandrel 17 , the secondary forming 16 is subjected to spinning processing using rollers 18 and 19 so that the rim 2 of a cross-sectional form as shown in FIG. 2 is obtained.
  • the disk 3 is fabricated by forming metal material into a disk form by widely known manufacturing methods such as casting, press-forming, and forging or the like using aluminum alloys and other lightweight metal material.
  • the disk 3 and the rim 2 are subjected to degreasing, water rinsing, acid treatment, water rinsing, copper plating, water rinsing, nickel plating, water rinsing, and chromium plating successively so as to form a chromium plating layer on a whole surface with two layers of copper and nickel used as substrate layers on the disk 3 and the rim 2 .
  • the welding planned portions RW and DW on the rim 2 and the disk 3 are ground to remove the chromium plating on the welding planned portions.
  • the disk 3 When plating of the welding plating portion DW on the disk 3 is ground and removed, the disk 3 is set to a rotary table, and the welding planned portion on an outer circumferential part of the disk 3 is subjected to a grinding treatment by a portable grinder while rotating the disk 3 together with the rotary table, thereby the chromium plating of the welding planned portion is removed.
  • the disk 3 it is possible to provide a configuration to prevent a formation of plating on the welding planed portion by carrying out a plating treatment with a masking tape affixed to the welding planned portion at the time of plating, so as to omit the plating removal process.
  • a plating removing apparatus 20 with a configuration as shown in FIG. 6 is used to remove plating of the welding planned portion RW by grinding the plating of the welding planned portion RW using an abrasive cloth/paper composed with a grinding belt 29 .
  • the plating removing apparatus 20 is equipped with a pair of support rollers 21 horizontally arranged by setting center axes thereof in parallel at an interval smaller than an outer diameter of the rim, a positioning member 22 for positioning the rim 2 supported on the support rollers 21 with a center axis thereof made substantially horizontal in the axial direction of the support roller 21 , a pair of holding rollers 23 arranged substantially in parallel to the support roller 21 above the support roller 21 , and actuator 32 for holding the rim 2 between the support roller 21 and the holding roller 23 by pressing the rim 2 positioned and held on the support roller 21 from an upper side by the holding roller 23 , a rotation drive means 24 for rotating and driving the rim 2 held between the support rollers 21 and holding rollers 23 , and a grinding means 25 that extends to an inside of the rim 2 for grinding the welding planned portion RW of the rim 2 with respect to the disk 3 so as to remove plating of the welding planned portion RW.
  • the grinding means 25 is configured to have a drive pulley 26 supported rotatably around a center axis thereof substantially in parallel to the center axis of support rollers 21 , an idler pulley 27 arranged with a center axis thereof made substantially vertical, a grinding belt 29 stretched between both the drive pulley 26 and the idler pulley 27 with a direction thereof changed at a halfway part by guide rolls 28 , a drive means 30 for grinding that rotates and drives the drive pulley 26 , and a pressurizing cylinder 31 for pressing the grinding belt 29 stretched to the drive pulley 26 against a welding planned portion on the rim 2 , so as to grind a bottom part of an inner circumferential surface of a rim by the grinding means 25 .
  • a peripheral velocity of the grinding belt 29 with respect to the welding planned portion RW is set to 150 to 600 m/min
  • the pressurizing force with respect to the rim 2 is set to be 0.5 kN to 1.5 kN
  • a rotating speed of the rim 2 is set to be 5 to 100 rpm so that a grinding treatment can be implemented for the welding planned portion RW during a single rotation of the rim 2 .
  • a width of the grinding belt 29 is set to be equal to or slightly larger than that of the welding planned portion RW so that plating of the welding planned portion RW can be ground by a single grinding treatment.
  • grinding can be divided into multiple steps of grinding in the axial direction.
  • this plating removing apparatus 20 When this plating removing apparatus 20 is used to grind a welding planned portion on an inner circumferential surface of the rim 2 , the rim 2 is placed on the support rollers 21 with a center axis thereof directed in the horizontal direction first, and then an end of the rim 2 is brought in contact with the positioning member 22 to position and set the rim 2 in the horizontal direction on the support rollers 21 as shown in FIG. 7 ( a ) so that the holding rollers 23 are protruded downward by the actuator 32 to hold the rim 2 between the support roller 21 and the holding roller 23 as shown in FIG. 7 ( b ).
  • the grinding means 25 is moved from a retracted position shown in FIG. 6 and FIG. 7 ( c ) to an advancing position as shown in FIG. 8 ( a ), in which the support roller 21 is rotated by the rotation drive means 24 to rotate the rim 2 at low speed with a rotating speed of, for example, 10 rpm, while allowing the grinding belt 29 to orbit, and pressing and bringing the grinding belt 29 applied to the drive pulley 26 to be in contact with the welding planned portion RW on a bottom part of the inner circumferential surface of the rim 2 rotating at low speed, so that the welding planned portion RW of the rim 2 rotating at low speed is successively ground, and plating in the welding planned portion RW is successively removed as shown in FIG. 8 ( b ).
  • the grinding belt 29 is separated from the inner circumferential surface of the rim 2 , and a rotation of the rim 2 by the drive means 30 for grinding is stopped, in which a drill 34 is raised to form a valve fixing hole (refer to FIG. 2 ) while the drill 34 is being rotated by the drill drive means 33 as shown in FIG. 8 ( c ).
  • a drill 34 is raised to form a valve fixing hole (refer to FIG. 2 ) while the drill 34 is being rotated by the drill drive means 33 as shown in FIG. 8 ( c ).
  • a side edge of the grinding belt 29 is subtly bent as shown in FIG. 9 while the welding planned portion RW is ground by the grinding belt 29 , a base material surface 2 a of the welding planned portion RW in which plating was removed and a surface of the plated area 2 b is smoothly connected without forming a level difference at a boundary 2 c between the base material surface 2 a and the plate area 2 b , thereby effective preventing nonconformity including exfoliation of the plated area 2 b from the boundary 2 c during welding or others.
  • removal of plating of the welding planned portion RW by grinding enables to neatly remove plating of the welding planned portion RW in a substantially complete state, and welding defects of the disk 3 with respect to the rim 2 can be securely prevented.
  • a labor cost used for a plating treatment can be minimized and a manufacturing cost of the wheel 1 can be reduced.
  • a bottom part of an inner circumferential surface of the rim 2 is ground in a state that the rim is held by the support rollers 21 , even when a plated area of the rim 2 with a different size is removed, a grinding portion in the inner circumferential surfaces of rims 2 is substantially the same without causing an adjustment of a relationship in height between the grinding means 25 and the rim 2 , thereby a plating removal operability can be remarkably improved.
  • grinding can be carried out by the use of the grinding belt 25 , it is made possible to increase a durability of the grinding belt 29 as a grinding tool while the drive pulley 26 inserted inside the rim 2 is made compact, and a grinding operation can be efficiently carried out.
  • a position adjusting means that adjusts a position to be ground by the grinding means 25 in the axial direction of the rim 2 , and in such event, an axial position of the welding planned portion RW can be optionally adjusted, thereby a wheel can be fabricated by adjusting a mounting position of the disk 3 with respect to the axial direction of the rim 2 in accordance with a request from a user.
  • plating of the welding planned portion RW can be removed by grinding, plating can be removed by a plating removing apparatus with a configuration other than that of the plating removing apparatus 20 .
  • the rim 2 is heated by an induction heating apparatus, and an inside diameter of the rim 2 is expanded by thermal expansion, in which the disk 3 is inserted into a setting position inside the rim 2 in the axial direction and a temperature of the rim 2 is lowered by air cooling, so that the disk 3 is fitted and fixed to an inside of the rim 2 by shrink fitting.
  • TIG welding or MIG welding is carried out to successively weld and join the welding planned portions DW and RW of the disk 3 and the rim 2 , and to obtain a two-piece wheel 1 as shown in FIG. 1 and FIG. 2 .
  • the welding planned portion RW on an inner circumferential surface of the rim can be easily and neatly ground with accuracy by grinding, enabling a low manufacturing cost of the two-piece wheel 1 with the rim 2 plated by chromium.
  • the three-piece wheel 51 has a substantially cylindrical outer rim 52 A and inner rim 52 B which have an annular superimposed part 52 a extending to an inner side on one end part, and a disk 54 fixed to the superimposed part 52 a of both of the outer rim 52 A and the inner rim 52 B with a bolt not shown.
  • the disk 54 which is integrally formed using aluminum alloys and other lightweight metal material by casting, press-forming, and forging or the like is equipped with a fixing part 55 to a wheel support member (omitted from drawings), an annular ring part 56 installed in such a manner as to surround and enclose the fixing part 55 and a spoke part 57 that joins the fixing part 55 to the ring part 56 , in which a whole surface thereof is subjected to a chromium-plating treatment.
  • the plating treatment is carried out by a widely known method to immerse the disk 54 in plating liquid.
  • the disk 4 is not necessarily provided with the plating treatment and may be provided with coating.
  • Both the outer rim 52 A and the inner rim 52 B are composed with metal material with superb stretchability such as aluminum alloys and others.
  • a whole surface of the outer rim 52 A is subjected to a plating treatment such as chromium plating and other plating by a widely known method to immerse the outer rim 52 A in plating liquid in order to improve design features thereof.
  • the inner rim 52 B may be provided with a chromium plating treatment in the same manner with the outer rim 52 A, but an alumite treatment which can be implemented at low cost is provided for the inner rim 52 B which has little effect on the design features.
  • a substantially cylindrical body part 52 b linked to the superimposed part 52 a is formed, and flange parts 52 c are formed with a wall thickness increased to have wall thicker than other parts at the end part on the design surface side of the outer rim 52 A and the end part on the fixing surface side of the inner rim 52 B, respectively.
  • the flange parts 52 c are thus configured to be thick by increasing the wall thickness, thereby when the outer rim 52 A is subjected to a plating treatment, plating liquid or the like is securely prevented from remaining inside the flange parts 52 c and corrosion of the flange parts 52 c caused by the remaining plating liquid can be prevented.
  • the wall thickness configured on the flange part 52 c of both the outer rim 52 A and the inner rim 52 B is sufficiently secure, strength and rigidity of a wheel 51 can be satisfactorily secured during rotation or the like.
  • the welding planned portions R are respectively formed with plating and oxide film removed to expose the base material.
  • Plating of the welding planned portion R on the outer rim 52 A is removed by a plating removing apparatus 60 discussed later to expose the base material while oxide film of the welding planned portion R of the inner rim 52 B is removed by a wire brush or the like to expose the base material.
  • plating of the welding planned portion R is removed by the plating removing apparatus 60 later discussed in the same manner as the outer rim 52 A.
  • the superimposed parts 52 a of both the outer rim 52 A and the inner rim 52 B are superimposed, fixing this superimposed part 52 a to an outer circumferential part of the disk 54 with the bolt 53 and integrating both of the outer rim 52 A and the inner rim 52 B to the disk 54 into one, and welding both of the welding planned portions R from the outer circumferential side to assemble the wheel 51 .
  • This manufacturing method of the wheel 51 has a different content for the operation in each process of the embodiment described above but has similar processing steps as shown in FIG. 3 .
  • a configuration of the processing steps includes a rim manufacturing process for manufacturing the outer rim 52 A and the inner rim 52 B, a disk manufacturing process for manufacturing the disk 54 , a plating process for providing a chromium plating treatment to the outer rim 52 A and the disk 54 , a plating removing process for removing plating of the welding planned portion R of the outer rim 52 A with respect to the inner rim 52 B, and an assembly process for assembling the wheel 51 from both of the outer rim 52 A and the inner rim 52 B and the disk 54 . Because the present invention is characterized by a configuration to easily and neatly remove plating of the welding planned portion R of the outer rim 52 A, processes other than the plating removing process of the outer rim 52 A will be briefly described.
  • a disk-form rolled metal plate 10 with superb stretchability such as aluminum alloy is press-formed to fabricate a primary forming 13 having a cylindrical tubular part 11 with a bottom 14 and a flange part 12 externally extending from an end part on an opening side of the tubular part 11 .
  • a primary forming 13 having a cylindrical tubular part 11 with a bottom 14 and a flange part 12 externally extending from an end part on an opening side of the tubular part 11 .
  • an axial length of the cylindrical part 11 is set to fit in an axial length of the outer rim 52 A
  • the inner rim 52 B is manufactured, it is set to fit in an axial length of the inner rim 52 B.
  • a primary forming 13 A is fabricated by removing a bottom part 14 of the primary forming 13 by punching processing or the like. Whole of the bottom part 14 of the primary forming 13 may be cut off, but a flange part that extending to a center part side may be formed by cutting off the center part only so that the flange part is used for a superimposed part 52 a . Then, the primary forming 13 A is externally fitted and fixed to a mandrel, rotating the primary forming 13 A together with the mandrel, carrying out spinning processing to the primary forming 13 A by using rollers, thereby the outer rim 52 A and the inner rim 52 B of a cross-sectional form as shown in FIG. 10 are obtained.
  • disk 54 is fabricated by forming metal material into a disk form by a widely known manufacturing method such as casting, press-forming, and forging using aluminum alloys and other lightweight metal material.
  • the disk 54 and the outer rim 52 A are subjected to degreasing, water rinsing, acid treatment, water rinsing, copper plating, water rinsing, nickel plating, water rinsing, and chromium plating successively so as to form a chromium plating layer on a whole surface with two layers of copper and nickel used as a substrate layer on the disk 54 and the outer rim 52 A.
  • the chromium plating can also be provided for the inner rim 52 B in the same manner with the outer rim 52 A, but an alumite treatment feasible at an inexpensive price is provided for the inner rim 52 B which has little affects on the design features.
  • plating of the welding planned portions R on the outer rim 52 A is removed by an abrasive cloth/paper 61 using the plating removing apparatus 60 of the following configuration and plating at the welding planned portions is ground and removed.
  • the plating removing apparatus 60 is equipped with a support means 62 that rotatably supports the outer rim 52 A with a center axis held substantially vertical, a rotation drive means 64 that rotates and drives the outer rim 52 A supported to the support means 62 held by three holding rollers 63 from the outer circumferential side, and a grinding means 65 that removes plating of the relevant welding planned portion R by grinding the welding planned portion R on the outer circumferential surface of the curved part of the outer rim 52 A with abrasive cloth/paper 61 .
  • the support means 62 is equipped with a rotary plate 67 which is rotatably supported by a support tube 66 and a jig plate 68 which is removably and externally fitted and fixed to the rotary plate 67 , in which it is configured to set the outer rim 52 A to the jig plate 68 with a center axis of the rim 52 A made substantially vertical to the jig plate 68 and the superimposed part 52 a side made to be in an upper side, so that the body part 52 b extends downwards from the superimposed part 52 a .
  • it is configured to support the outer rim 52 A of various sizes by the support means 62 by replacing the jib plate 68 with that of a different sized outside diameter.
  • the rotation drive means 64 is primarily composed of three holding rollers 63 rotatably installed with a center axes thereof made in the vertical direction at specified intervals in the circumferential direction on an outside of the outer rim 52 A supported by the support means 62 , an air cylinder 69 which pressurizes and brings the holding rollers 63 in contact with the flange part 52 c of the outer rim 52 A, and an electrically-driven motor 70 , in which the rotation drive means 64 for rotating and driving one holding roller 63 is configured to rotate the outer rim 52 A at low speed by rotating and driving one holding roller 63 with the rotation drive means 64 in a state that the outer rim 52 A is held by the three holding rollers 63 .
  • the grinding means 65 is equipped with a drive means 75 which has an electrically-operated motor 72 , a plurality of pulleys 73 , and a belt 74 stretched between the pulleys 73 , and an abrasive cloth/paper 61 including a flap wheel rotated and driven by the drive means 75 .
  • abrasive cloth/paper 61 it is possible to use those other than the flap wheel.
  • this grinding means 65 is configured to be capable of adjusting a position thereof in such a manner that the abrasive cloth/paper 61 is pressurized and brought in contact substantially vertical to the welding planned portion R by an elevating means and a horizontal moving means not shown.
  • a rotating speed of the outer rim 52 A can be optionally set, but in order to sufficiently secure the processing capacity and surface properties of a grinding surface, the rotating speed of the outer rim 52 A is set to be, for example, 5-100 rpm, and a rotating speed of the abrasive cloth/paper 61 is set to be 1500-3000 rpm, and the pressurizing contact force of the abrasive cloth/paper 61 with respect to the outer rim 52 A is set to be 0.5 kN-1.5 kN so as to provide a configuration that the welding planned portion R can be ground during a single rotation of the outer rim 52 A.
  • a width of the abrasive cloth/paper 61 is preferably set to be slightly larger than that of the welding planned portion R so that plating of the welding planned portion R can be ground and removed by a single grinding treatment.
  • the jig plate 68 suitable for an inside diameter size of the outer rim 52 A subjected to a grinding treatment is set to the rotary plate 67 , and then the outer rim 52 A is set with a center axis thereof made substantially vertical to the jig plate 68 , and the superimposed part 52 a side made to be in an upper side in such a manner that the body part 52 b extends downwards from the superimposed part 52 a.
  • the holding rollers 63 are allowed to advance by the air cylinder 69 and an outer circumferential part of the flange part 52 c set to the support means 62 is held by the three holding rollers 63 .
  • a vertical directional position and a longitudinal directional position of the abrasive means 65 are adjusted in such a manner that the abrasive cloth/paper 61 faces the welding planned portion R of the outer rim 52 A with a subtle clearance provided in accordance with the size of the outer rim 52 A.
  • the abrasive cloth/paper 61 is rotated by the electrically-operated motor 72 , the abrasive cloth/paper 61 is pressed and brought in contact with the welding planned portion R of the outer rim 52 A by the pressurizing cylinder 76 , so as to grind plating of the welding planned portion R.
  • the abrasive cloth/paper 61 is pressed and brought in contact with a center part in a substantially vertical state, and an outer circumferential surface of the abrasive cloth/paper 61 is deformed in such a manner that a center part thereof in the thickness direction is slightly dented along a curved surface of the welding planned portion R as shown in FIG.
  • the wide welding planned portion R is ground at a single time.
  • the base material area 58 a and the plated area 58 b of the welding planned portion R are smoothly linked and no level difference is formed at a boundary between the base material area 58 a and the plated area 58 b , therefore, exfoliation of the plated area 58 b can be effectively prevented.
  • the welding planned portion R is successively subjected to a grinding treatment, but the grinding treatment can be carried out during several rotations or the welding planned portion R may be divided into multiple portions in the width direction for the successive grinding.
  • the superimposed portions 52 a of both of the outer rim 52 A and the inner rim 52 B are superimposed while an outer circumferential part of the disk 54 is fixed to this superimposed part 52 a with the bolt 53 to integrate both of the outer rim 52 A and the inner rim 52 B to the disk 54 into one, after which the welding planned portions R of both of the outer rim 52 A and the inner rim 52 B are successively welded and joined from an outer circumferential side of the inner rim 52 B by TIG welding or MIG welding, and a three-piece wheel 51 as shown in FIG. 10 is obtained.
  • the welding planned portion R of an outer circumferential surface of the curved part linked from the superimposed part 52 a to the cylindrical part 52 b of the inner rim 52 B can be ground.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Arc Welding In General (AREA)
  • Butt Welding And Welding Of Specific Article (AREA)
  • Polishing Bodies And Polishing Tools (AREA)
US11/512,329 2005-09-01 2006-08-30 Method for manufacturing wheels Abandoned US20070044311A1 (en)

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Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN103492194A (zh) * 2011-05-09 2014-01-01 都美工业株式会社 车辆用轮辐
CN107539014A (zh) * 2016-06-27 2018-01-05 张能 一种轿车轮毂
US20190202020A1 (en) * 2017-12-29 2019-07-04 Citic Dicastal Co., Ltd Device for removing tool joint edge burrs from cap opening of wheel
US11213925B2 (en) * 2017-10-31 2022-01-04 Citic Dicastal Co., Ltd Device for removing burrs from riser of aluminum alloy wheel
CN114619189A (zh) * 2022-05-12 2022-06-14 苏州超莱斯机器人科技有限公司 一种汽车配件焊接机器人
CN117484056A (zh) * 2023-11-30 2024-02-02 山东山工钢圈有限公司 一种车轮轮辋加工用焊接固定装置

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JP2008303457A (ja) * 2007-06-11 2008-12-18 Orion Mach Co Ltd 熱交換器用パイプの防錆方法及び熱交換器用パイプ並びに熱交換器の防錆方法及び熱交換器
FR2920681B1 (fr) * 2007-09-10 2009-12-04 Snecma Utilisation d'un flux activant pour le soudage tig de pieces metalliques
US8353106B2 (en) * 2009-07-06 2013-01-15 Rimsmith Tool, LLC Wheel/rim fixing device and method of using the same

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US4898649A (en) * 1988-02-27 1990-02-06 Nkk Corporation Method for manufacturing electrolytically chromated steel sheet
US5435629A (en) * 1991-07-09 1995-07-25 Embishi Aluminum Wheels Ltd. Wheel for vehicle
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Cited By (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN103492194A (zh) * 2011-05-09 2014-01-01 都美工业株式会社 车辆用轮辐
US9327547B2 (en) 2011-05-09 2016-05-03 Topy Kogyo Kabushiki Kaisha Vehicle wheel disk
CN107539014A (zh) * 2016-06-27 2018-01-05 张能 一种轿车轮毂
US11213925B2 (en) * 2017-10-31 2022-01-04 Citic Dicastal Co., Ltd Device for removing burrs from riser of aluminum alloy wheel
US20190202020A1 (en) * 2017-12-29 2019-07-04 Citic Dicastal Co., Ltd Device for removing tool joint edge burrs from cap opening of wheel
US10780545B2 (en) * 2017-12-29 2020-09-22 Citic Dicastal Co., Ltd Device for removing tool joint edge burrs from cap opening of wheel
CN114619189A (zh) * 2022-05-12 2022-06-14 苏州超莱斯机器人科技有限公司 一种汽车配件焊接机器人
CN117484056A (zh) * 2023-11-30 2024-02-02 山东山工钢圈有限公司 一种车轮轮辋加工用焊接固定装置

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US20110107599A1 (en) 2011-05-12
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