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Optimum Design of Forming Sequence of One-Piece Automobile Steel Wheels without Welding Using Finite Element Simulation

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Abstract:

A forming sequence of one-piece automobile steel wheels without welding was designed. In this forming process, the one-piece wheel was formed from a circular blank only by multi-stage stamping operations, and a deeply drawn cup was formed into the wheel. Two humps of the rim flange for fixing the tire were formed in the flaring and flanging stages. The humps of the rim in the opening and outer side were formed by buckling the inner flange of the rim, and by swelling the outer flange with an upper die having a short land, respectively. In addition, the number of stages was considerably reduced from 16 stages to only 9 stages by combining the deep drawing and ironing stages and by adding a holding die in the flaring stages. The forming sequence of the one-piece wheels was evaluated by both finite element simulation and miniature experiment.

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Periodical:

Key Engineering Materials (Volumes 340-341)

Pages:

773-778

DOI:

https://doi.org/10.4028/www.scientific.net/KEM.340-341.773

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Online since:

June 2007

Authors:

Y. Abe, J. Watanabe, Kenichiro Mori

Keywords:

Finite Element (FE) Simulation, Flange Forming, Miniature Experiment, Multi-Stage Stamping, One-Piece Steel Wheel, Process Design, Sheet Metal Forming, Wall Thickness Reduction

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© 2007 Trans Tech Publications Ltd. All Rights Reserved

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