ALUMINIUM ALLOY WHEELS

GROUP 11
ANISH K

10093

SIDDHARTH RAWAT

10710

YASH CHOUDHARY

10823

INTRODUCTION
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.2

PROPERTIES REQUIRED

Stiffness.

Fatigue Strength.

Yield Strength.
Temperature & Corrosion
resistance.
Impact Resistance.
Reduced Weight.

MANUFACTURING STEPS
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

DIFFERENT TYPES OF CASTING

LOW PRESSURE
DIE CASTING

PERMANENT
MOLD CASTING

FLOW FORMING
(RIM ROLLING)

Begins with LPDC.

Steel rollers push

against the rim area
to its final dimension.

Produces light and

strong wheels at
reasonable costs.

Metal stored in
crucible.
Air at Pressure(15100 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 molds
made of carbon
steels or grey cast
iron.

Molten metal poured

into the permanent
mold.

Molten Al
pressurized into
negative cavity of
mold.
Setup for LPDC
Ensures no voids
created in the cast.

Temp. increased to
300-3500C.

FORGING
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.

SHEET METAL PROCESS

FINISHING OPERATIONS
Machining and finishing to remove

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.

protruding parts and defects

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

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.

COMPARISON
CAST WHEELS

FORGED WHEELS

Low cost of production.

Mediocre fatigue performance.

Relatively expensive.

Better mechanical properties than

cast wheels.

Could fail due to sudden impacts

( hitting curbs and potholes).

Higher safety due to absence of

pores and cavities.

Can bear higher loads than cast

wheels.

Large variety of surface finishes

can be applied.

Can perform at par with forged

wheels under normal loading
conditions.

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 POLISHING
Very good surface finish.
High strength ceramic particles used.
Removes brittleness to a certain extent.

MODERN TECHNOLOGIES

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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CONCLUSION

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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THANK YOU !!

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