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Development of One-piece Reverse Rim Aluminum Alloy Wheel Using Flowforming Process

Article of Honda R&D Technical Review Vol.32 No.2

Summary

In an attempt to increase freedom of design in automobiles, a method of manufacturing aluminum wheels with a reverse rim configuration that realizes lower weight and lower cost has been developed. The configuration of the molds and the machining process for the rim in the GDC flowforming process were modified, and the machining method and machining conditions were optimized. This made one-piece manufacture of reverse rim wheels possible. CAE analysis verified that by converting wheels to reverse rim types, it would be possible to reduce the excessive thickness between the disk surface and the bead drop area of the wheel, reducing the weight of wheels of 18 inches or more in diameter by 5% or more. Next, a prototype of an 18-inch wheel was produced, and it was verified that its weight was reduced in accordance with CAE results. In addition, a prototype of a wheel employed in sports-type vehicles was produced, and it was verified that a weight reduction of 2% or more had been achieved despite the fact that the wheel had been designed to realize reduced weight.

Reference

(1) Aoyama, M.: Part 10 Soko sochi, Kuruma no shikumi, Natsumesha CO., LTD., p. 173, (2008) (in Japanese)
(2) Nozaki, H.: Kisojidosya kogaku, Taiya no rikigaku, Tokyo Denki University Press, p. 5, (2017) (in Japanese)
(3) The Society of Materials Science, Japan: Chapter 3, Kyodo no kihontokusei: Kaitei zairyo kyodogaku, p. 50, (2009) (in Japanese)
(4) Japan Institute of Light Metals: Chapter 8, Kogyoyo zairyo: Aruminiumu zairyo no kiso to kogyogijyutsu, p. 306, (1985) (in Japanese)

Author (organization or company)

Masayoshi OHASHI(Honda Motor Co., Ltd.)、Muneyoshi SAWAI(Honda Motor Co., Ltd.)、Tomonori SAKAI(Honda Motor Co., Ltd.)、Erina KOBAYASHI(Honda Motor Co., Ltd.)、Hideyuki SUZUKI(KOSEI ALUMINUM Co., LTD.)、Minoru KAWAKAMI(KOSEI ALUMINUM Co., LTD.)

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