Brief presentation on the manufacture of Aluminium alloy wheels by various methods and the innovations of the present. Made with the help of Siddharth Rawat and Yash Choudhary PS: Download and view in powerpoint for effects.. some text are hidden by pictures.

1. ALUMINIUM ALLOY WHEELS
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2. • Invented in 1948.
• First Al wheel – forged.
• Used initially because of aesthetic appeal.
• Today 50% wheels are Al wheels.
• Lighter while providing same strength.
• Components
Wheel hub.
Spokes.
Rim.
• Reasons for using Aluminium
Improved car handling and riding
comfort.
Improved grip.
Reduced fuel consumption.
Better braking performance.
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3.  Processes 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
 Stiffness.
 Yield Strength.
 Temperature & Corrosion
resistance.
 Fatigue Strength.
 Impact Resistance.
 Reduced Weight.
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4. 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.
PERMANENT MOLD
CASTING
• Permanent molds made of
carbon steels or grey cast
iron.
• Molten metal poured into
the permanent mold.
• Molten Al pressurized into
negative cavity of mold.
• Ensures no voids created
in the cast.
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.
Setup for LPDC 4

5. Single 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. 5

6. 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.
FINISHING OPERATIONS
 Machining 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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7. • 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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8. CAST WHEELS
• Low cost of production.
• Mediocre fatigue performance.
• Could fail due to sudden impacts ( hitting
curbs and potholes).
• Can perform at par with forged wheels
under normal loading conditions.
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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9. • AIR INSIDE Technology
Hollow chambers and spokes.
Reduces weight – better driving experience and comfort.
Increases load bearing ability by up to 60%.
• CERAMIC POLISHING
Very good surface finish.
High strength ceramic particles used.
Removes brittleness to a certain extent.
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10. • NANO PAINTWORK
Heat and scratch resistant.
Repels dirt, dust, water and other liquids.
• FABRICATION
Assembly 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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11. • Aluminium wheels are most widely used in the world.
• Aluminium alloy wheels 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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12. THANK YOU !!
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