PRESENTED BY :-NAME :- PANKAJ KUMAR DALAISEMESTER :- 8TH

REGD. NO. :- 1101225142ROLL NO. :- 11-ME/76

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ALLOY WHEEL MANUFACTURING

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CONTENTS Introduction History Components Of Alloy Wheel Reasons For Using Aluminum Properties Required Manufacturing Steps Different Types Of Casting Sheet Metal Process Finishing Operations Critical Analysis Comparison Modern Technologies Conclusion

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INTRODUCTIONAlloy wheels are wheels that are made from an alloy of aluminium or magnesium. They are typically lighter for the same strength and provide better heat conduction and improved cosmetic appearance over steel wheels.

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HISTORY• Invented in 1948.

• First Al wheel – forged.

• Earliest alloy wheels were made of magnesium.

• Used initially because of aesthetic appeal.

• Today 60% wheels are Al wheels.

• Lighter while providing same strength.

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Wheel hub.

Spokes.

Rim.

Components Of Alloy Wheel

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Reasons for using Aluminum

Improved car handling and riding comfort.

Improved grip.

Reduced fuel consumption.

Better braking performance.

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PROPERTIES REQUIRED Stiffness. Yield Strength. Temperature & Corrosion resistance. Fatigue Strength. Impact Resistance. Reduced Weight.

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MANUFACTURING STEPSProcesses used for manufacture of Al wheels.

Casting Forging Sheet Metal Process

Final finishing operations. Painting Varnishing Polishing followed by a clear coating Chrome Wheel Finish

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DIFFERENT TYPES OF CASTING

LOW PRESSURE DIE CASTING

PERMANENT MOLD CASTING

FLOW FORMING (RIM ROLLING)

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Setup for LPDC

LOW PRESSURE DIE CASTING

• Metal stored in crucible.• Air at Pressure(15-100 kPa) introduced.• Molten metal rises into the cavity

between the dies.• The metal solidifies.• The pressure is released after which the

die is opened and casting taken out.

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PERMANENT MOLD CASTING

• Permanent molds made of carbon steels or grey cast iron.

• Molten metal poured into the permanent mold.

• The molds are heated to approximately 500 degrees Fahrenheit. 

• Ensures no voids created in the cast.

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FLOW FORMING (RIM ROLLING)

• Begins with LPDC.• Temp. increased to 300-3500C.• Steel rollers push against the rim area

to its final dimension.• Produces light and strong wheels at

reasonable costs.

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FORGINGSingle block of high strength alloy.

Forged into basic wheel shape with 8000 ton press.Strength maximized by heat treatment.

Machined to ensure desired shape.

Drilling of holes and ventilation.Polishing to give a shine.Etching and painting.

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SHEET METAL PROCESS Large strip cut into two round shapes. Ends welded together. Rims shaped by rolling. Nave produced by deep

drawing/stamping. Joining of nave and rims. Surface treatment and coating.

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FINISHING OPERATIONSMachining and finishing to remove

protruding parts and defects during initial processes.

Fine polishing to enhance shine of surface.Chrome wheel finish.Polished clear coat finish.Painting and varnishing.

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CRITICAL ANALYSIS• Difficult step in casting – mold preparation – high complexity of

shapes.• Some properties may get compromised while reducing weight –

wheel blank heated under pressure.• Grains get aligned along one direction during forging – gives

better damage tolerance, increased strength and toughness.• Forged wheels are non – porous and have fine microstructure. Hence they have high fatigue resistance.

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COMPARISONCAST WHEELS

• Low cost of production.• Mediocre fatigue

performance.• Could fail due to sudden

impacts (hitting curbs and potholes).• Can perform with forged

wheels under normal loading conditions.• Small variety of surface

finishes can be applied.

FORGED WHEELS• Relatively expensive.• Better mechanical properties

than cast wheels.• Higher safety due to absence

of pores and cavities.• Can bear higher loads than

cast wheels.• Large variety of surface

finishes can be applied.

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MODERN TECHNOLOGIES• AIR INSIDE TECHNOLOGY

Hollow chambers and spokes.Reduces weight – better driving experience and comfort.Increases load bearing ability by up to 60%.

• CERAMIC POLISHINGVery good surface finish.High strength ceramic particles used.Removes brittleness to a certain extent.

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MODERN TECHNOLOGIES• NANO PAINTWORK

Heat and scratch resistant.Repels dirt, dust, water and other liquids.

• FABRICATIONAssembly of multiple components to produce finished

wheel.Titanium bolts which impart high strength and minimize

failure chances are used.Easy replacement of components.

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CONCLUSION• Alloy wheels are most widely used in the world.• Alloy wheels are better than conventional steel

wheels.•Most widely used processes - casting and forging.• Forged wheels are better than those made by

Casting.Better impact resistance.Fatigue performance.High durability.Lightweight.

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THANK YOU !!