Finite element software is systematically used during design. This is the most important parameter for dimensioning. Yield tests under pressure are also conducted to check this behaviour. Misuse cases are considered in relation to tensile strength. Yield strength is considered to avoid deformation under maximal axial efforts (accelerations and braking) and radial ones (plus turning). However, material stiffness ( Young’s modulus) is very little depending on alloy and temper. Structural stiffness (design dependent) is the basic value to consider when designing an aluminium wheel to achieve at least the same vehicle behaviour as with an equivalent steel wheel. These components have, however, critical safety functions and must meet high standards of design, engineering and workmanship Design/material selection considerations Stiffness Wheels are now representing about 15% of the average aluminium content in passenger cars and light trucks, and if the main motivation has been styling with mainly cast solutions, weight reduction requirements have lead to the development of more technical cast but also forged and fabricated solutions. Mainly cast at this time, they started in the 1970s to be factory-fitted to mass-produced cars. Using aluminium wheels on passenger cars began with the upper class or flagships models in order to give them a distinctive personal touch. Through further development of the production process for wheel rims and naves, the manufacturing costs were reduced markedly so that an aluminium sheet wheel has been produced in large numbers for the BMW 5 Series since 1995 The first high-volume production of sheet wheels in Europe started in 1979 for Daimler-Benz cars destined for the USA. In the 1960s, Porsche began the batch production of sheet wheels, which consisted of a wheel rim and nave. The first light-alloy sheet aluminium car wheels were used in Daimler-Benz and Auto-Union racing cars in the 1930s. Alloy wheel material has evolved too: car wheels alloys now contain 7 to 12% silicon content, and varying contents of magnesium in addition to aluminium, in order to meet the demand for metal-mould casting properties, corrosion and fatigue resistance. Due to sophisticated wheels design, casting has become the dominant manufacturing process. Learn about the most popular alloy wheel composition components, some of which might surprise youĪluminium alloy wheels manufacturing process have developed a lot since 1970s.Find out about alloy wheel material selection considerations and casting process options, plus secondary processing methods.This article concisely covers key areas concerning aluminium alloy wheels manufacturing process.
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