DESC:A HIGH PERFORMANCE LIGHT WEIGHT WHEEL FOR PASSENGER CARS

FIELD OF INVENTION
[0001] The embodiment herein generally relates to the wheels of the passenger car. More particularly, the present invention relates to a high performance light weight wheel for passenger cars.
BACKGROUND AND PRIOR ART
[0002] A car’s weight comprises the total weight of its parts. The total weight of the car impacts the car’s ability to accelerate, brake and steer.
[0003] Wheel weight plays a very vital role in determining the vehicle's overall ride, performance and feel. Reducing the total weight will enhance the vehicle's performance because less weight needs to be controlled and therefore, less energy is required.
[0004] Less total weight of the car may have a crucial role and positive impact on the overall performance and handling of the car. The reason behind this is that less mass needs to be moved and controlled which eventually reduces the energy requirement of the vehicle.
[0005] Weight of the wheels is included into the unsprung weight of the vehicle. The unsprung weight is the total weight total weight of the parts that are not supported by the car’s suspension.
[0006] The unsprung weight of the vehicle directs impacts the driving feel of the car. The lesser the amount of the unsprung weight, the more effectively the suspension will be able to do its stabilizing job on the uneven roads.
[0007] Therefore, reduced unsprung weight or reduced unsprung weight may result in an overall better handling of the car with better driving feel.
[0008] Additionally, there is an impact of rotational weight on the vehicle performance. The rotational weight is the weight of the parts that rotate, which directly plays a major role in the performance of the car.
[0009] The lower the weight of these components, lesser is the energy required to accelerate and decelerate the vehicle.
[00010] The light weight wheels provided in the prior arts have reduced the wheel weight by compromising on the overall wheel performance.
[00011] In some other prior arts, the wheels provided therein compromise with overall look and aesthetic appeal of the vehicle and wheel covers are often used to hide these wheels.
[00012] Therefore, there is a need in prior arts to develop a vehicle wheel for the passenger cars that is light weight, very high in performance and adds to the aesthetic beauty of the car.
OBJECTS OF THE INVENTION
[00013] Some of the objects of the present disclosure are described herein below:
[00014] The main objective of the present invention is to provide a light weight wheel.
[00015] Another objective of the present invention is to provide a light weight wheel for the passenger car.
[00016] Still another objective of the present invention is to provide a light weight wheel for the passenger car that gives high performance.
[00017] Yet another objective of the present invention is to provide a light weight wheel that gives high performance without compromising on the aesthetic appeal of the passenger car.
[00018] Another objective of the present invention is to provide a high performance light weight wheel that is corrosion resistant.
[00019] Another objective of the present invention is to provide a high performance light weight wheel that has an alloy wheel look.
[00020] Another objective of the present invention is to provide a high performance light weight wheel that is light in comparison to other wheels.
[00021] Another objective of the present invention is to provide a high performance light weight wheel which can be used without cover because of styling which looks like alloy wheel.
[00022] Another objective of the present invention is to provide a high performance light weight wheel in which shifting of high stress zones is possible.
[00023] The other objectives and advantages of the present invention will be apparent from the following description when read in conjunction with the accompanying drawings, which are incorporated for illustration of preferred embodiments of the present invention and are not intended to limit the scope thereof.
SUMMARY OF THE INVENTION
[00024] In view of the foregoing, an embodiment herein provides a high performance light weight wheel for passenger cars.
[00025] According to an embodiment, the invention comprises a light weight wheel for the passenger cars that may have localized thinning at the lower stress zone.
[00026] According to an embodiment, in the optimized wheel provided herein, the process of selective material removal may be carried out either by milling or by non conventional material removal process.
[00027] According to an embodiment, in the design of the optimized steel wheel provided herein a special coating is provided in order to address the corrosion issues of the wheel.
[00028] According to an embodiment, the method for producing a light weight wheels comprises the following steps. First, analyzing a design of a wheel for identifying high stress zones and low stress zones on the wheel, determining a depth of machining for removing material from the low stress zones and determining a shape for removing material from the low stress zones. Next, removing material with the determined depth and shape from the identified low stress zones of the wheel and painting the wheel for finishing.
[00029] According to an embodiment, the depth of machining is determined using Experimental Stress Analysis. In an embodiment, the depth of machining is in a range of 10 microns to half of thickness of disc or rim.
[00030] According to an embodiment, the high stress zones and low stress zones are identified using Experimental Stress Analysis or Finite Element Analysis.
[00031] According to an embodiment, a weight of material for removing from the wheel is in a range of 5 milligrams to 500 grams.
[00032] According to an embodiment, material removal is performed using a non-conventional milling process.
[00033] These and other aspects of the embodiments herein will be better appreciated and understood when considered in conjunction with the following description and the accompanying drawings. It should be understood, however, that the following descriptions, while indicating preferred embodiments and numerous specific details thereof, are given by way of illustration and not of limitation. Many changes and modifications may be made within the scope of the embodiments herein without departing from the spirit thereof, and the embodiments herein include all such modifications.
BRIEF DESCRIPTION OF DRAWINGS
[00034] The detailed description is set forth with reference to the accompanying figures. In the figures, the left-most digit(s) of a reference number identifies the figure in which the reference number first appears. The use of the same reference numbers in different figures indicates similar or identical items.
[00035] Fig. 1.1 illustrates front view of the light weight vehicle wheel, according to an embodiment of the present invention herein;
[00036] Fig 1.2 illustrates rim portion of the light weight vehicle wheel, according to an embodiment herein;
[00037] Fig 1.3 illustrates front view of another type of vehicle wheel, according to an embodiment herein;
[00038] Fig. 2 illustrates cross sectional view of the light weight vehicle wheel, according to an embodiment of the present invention herein; and
[00039] Fig.3 illustrates a flow chart for the method of producing the light weight wheel, according to an embodiment herein.
LIST OF NUMERALS
100 - Light weight wheel
101 - Nave region
102 - Crown region
103 - Nave to crown region
104 - Vent hole region
105 - Rim flange
106 - Inner surface of rim
107 - Edge of the rim
201 - Depth of material
300 - Flow chart of method for producing light weight wheel

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[00040] The embodiments herein and the various features and advantageous details thereof are explained more fully with reference to the non-limiting embodiments and detailed in the following description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.
[00041] As mentioned above, there is a need to a light weight vehicle wheel that gives high performance without compromising on the aesthetic appeal of the passenger car. The embodiments herein achieve this by providing an optimized steel wheel which may have localized thinning at the lower stress zone.
[00042] Referring now to the drawings, and more particularly to Fig.1.1 through Fig.3, where similar reference characters denote corresponding features consistently throughout the figures, there are shown preferred embodiments.
[00043] Fig 1.1 illustrates front view of the light weight vehicle wheel, according to an embodiment of the present invention. According to an embodiment, for the purpose of the design of the optimized steel wheel the process of selective material removal is carried out.
[00044] According to an embodiment, the selective material removal is carried out either by milling or by non conventional material removal process.
[00045] According to an embodiment, the machining will be at specific regions with prescribed depth of material removal.
[00046] According to an embodiment, the depth of machining is finalized based upon the stress results simulated prior to design freeze or by obtaining strain values from ESA study in existing wheels.
[00047] According to an embodiment, the Finite Element Analysis (FEA) simulation is carried out in CAD first to identify the high stress zone and low stress zone areas. The Finite element analysis (FEA) is a computerized method for predicting how a product reacts to real-world forces, vibration, heat, fluid flow, and other physical effects. Finite element analysis shows whether a product will break, wear out, or work the way it was designed.
[00048] Alternatively, Experimental Stress Analysis (ESA) study may be carried out in physical parts to identify the high or low stress zones, according to an embodiment.
[00049] The material removal may be done from the non-stress zone by milling or by any non conventional process, according to an embodiment herein.
[00050] The Fig 1.1, 1.2 shows the front view 100, side view 100 of the wheel wherein various parts of wheel like Nave region 101, Crown region 102, nave to crown region 103, vent hole region 104, rim flange 105, inner surface of rim 106 and edge of the rim 107 are depicted, according to an embodiment.
[00051] According to an embodiment, a nave 101 is the middle body of the wheel, alternatively known as the hub of the wheel. The wheel hub transfers the vertical load from the wheel to the axle. It also transfers any lateral load as well, according to an embodiment.
[00052] According to an embodiment, for the purpose of the material removal in non stress zone, conventional process machining may be done. Conventional process machining may be carried out subjected to finish level to have consistency in life or to the acceptable limit of aesthetics.
[00053] According to an embodiment, the selective material removal may be done either in between or at the end of forming process.
[00054] Fig. 2 illustrates cross sectional view of the wheel, according to an embodiment of the present invention.
[00055] The depth of the material 201 removed may be based upon the stress plot with different shapes to reduce the stress levels at high stress zone or to change the failure zones from one region to other, according to an embodiment.
[00056] According to an embodiment, the depth of the material to be removed can vary between 10 micron to half of the thickness of disc or rim.
[00057] The depth of the material removed is dependent upon the design of the disc or rim and may vary accordingly, according to an embodiment.
[00058] According to an embodiment, the depth of the material to be removed and the shape of the pocket need to be controlled in case of shifting failure zone from one region to another.
[00059] According to an embodiment, the example of shifting of failure zone may be shifting of failure zone from vent hole to crown. In such instances the shape of the pocket and depth of the material to be removed may be controlled.
[00060] According to an embodiment, material removal helps in reaching the optimized wheel weight.
[00061] The weight reduction may vary from 5 milligrams to 500 grams depending upon the wheel size, parts base thickness and design of profile, according to an embodiment.
[00062] According to an embodiment, the wheel is also required to have a special ability to withstand corrosion.
[00063] A special painting process is carried out on the wheel for the purpose of addressing the issues in withstanding the corrosion problems, according to an embodiment.
[00064] A special coating is provided on this wheel so that it can with stand the corrosion related issues, according to an embodiment.
[00065] For the purpose of rendering anti corrosion properties to the wheel, the painting of the wheel may be done in three coats, according to an embodiment.
[00066] First a primer coat may be applied followed by a top coat and a lacquer coat, according to an embodiment herein.
[00067] According to an embodiment, alternatively any number of intermediate paint coatings may be applied between second and final coat to render anti-corrosive properties to the wheel, according to an embodiment.
[00068] The result of all the processes carried out above is the wheel, which is optimized by both performance and by weight, according to an embodiment.
[00069] According to an embodiment, there is no requirement of wheel cap for the optimized light weight wheel thus obtained.
[00070] According to an embodiment, since the design of the wheel may look like alloy wheel, the requirement of wheel cap is eliminated from the design, which renders the design superiority in terms of aesthetic appeal.
[00071] Also for the purpose of style improvement, material may be removed from multiple areas of the wheel, according to an embodiment.
[00072] According to an embodiment, after the material removal step is performed or the paint finishing step is carried out, different color paints may be provided for the localized pocket regions of the wheel.
[00073] According to an embodiment, alternatively to add to the overall aesthetic appeal of the wheel, add on material like sticker may also be applied post material removal or paint finishing on the wheel.
[00074] Fig. 3 illustrates a method for producing a light weight wheel, according to an embodiment. The method for producing a high performance light weight wheel for passenger cars includes the steps of, first analyzing 301 a design of a wheel. Then, identifying 302 a high stress zones and low stress zones on the wheel. In an embodiment, the high stress zones and low stress zones are identified using, but not limited to Experimental Stress Analysis, Finite Element Analysis.
[00075] Next, a depth of machining for removing material from the low stress zones of the wheel is determined 303. In an embodiment, the depth of machining for removing material is determined using Experimental Stress Analysis. In an embodiment, the depth of machining is in a range from 10 microns to half of thickness of disc or rim.
[00076] Next, a shape for removing material from the low stress zones of the wheel is determined 304.
[00077] Then, material is removed 305 from the identified low stress zones with the determined depth and shape for optimizing the weight of the wheel. In an embodiment, the material removal is performed using a non conventional milling process. In another embodiment, the material removal is performed using a milling process. In an embodiment, weight of material removed from the wheel is in a range of 5 milligrams to 500 grams.
[00078] Finally, the obtained wheel is painted 306 for finishing.
[00079] A main advantage of the present invention is that the optimized steel wheel provided herein is light in weight.
[00080] Another advantage of the present invention is that the optimized wheel provided herein is light weight and delivers high performance.
[00081] Still another advantage of the present invention is that the wheel provided herein is for use in passenger cars.
[00082] Yet another advantage of the present invention is that the wheel provided herein is corrosion resistant.
[00083] Another advantage of the present invention is that the light wheel looks like alloy wheels thereby adding to the aesthetic appeal of the vehicle.
[00084] Another advantage of the present invention is that the wheel looks like alloy wheel thereby eliminating the need to put wheel cap.
[00085] Another advantage of the present invention is that different color paintings or add on material may be added on the localized pocket regions of the wheel to enhance the look.
[00086] Another advantage of the present invention is that shifting of high stress zones from vent hole, nave, bolt hole or weld region is possible.
[00087] Another advantage of the present invention is that the deep drawn nave portion of the wheel gives it an alloy wheel look.
[00088] Another advantage of the present invention is that the material removal in non stress zone can be done by any one of milling or non conventional or conventional process.
[00089] Another advantage of the present invention is that the weight reduction of the wheel can vary from 5 milligrams to 500 grams depending upon the wheel size, parts base thickness and design of profile.
[00090] Another advantage of the present invention is that the localized material removal acts as a stress riser on the low stress zone which avoids the peak stress on the selective zone to improve the performance.
[00091] The foregoing description of the specific embodiments will so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the embodiments as described herein.
,CLAIMS:We claim:
1. A method for producing a light weight wheel, comprising the steps of:
analyzing 301 a design of a wheel;
characterized in that
identifying 302 high stress zones and low stress zones on the wheel;
determining 303 a depth of machining for removing material from the low stress zones;
determining 304 a shape for removing material from the low stress zones;
removing 305 material with the determined depth and shape from the identified low stress zones; and
painting 306 the obtained wheel for finishing.
2. The method as claimed in claim 1, wherein the depth of machining is determined using Experimental Stress Analysis.
3. The method as claimed in claim 1, wherein the high stress zones and low stress zones are identified using Experimental Stress Analysis or Finite Element Analysis.
4. The method as claimed in claim 1, wherein the depth of machining is in a range of 10 microns to half of thickness of disc or rim.
5. The method as claimed in claim 1, wherein a weight of material removal in a range of 5 milligrams to 500 grams.
6. The method as claimed in claim 1, wherein material removal is performed using a non-conventional milling process.