FIELD OF INVENTION
[001] The present invention relates to an automotive steel wheel rim more
particularly, to a process for manufacturing a flange ring for wheel rims utilized on
trucks and off-highway vehicles.
BACKGROUND/PRIOR ART OF THE INVENTION
[002] Background description includes information that may be useful in
understanding the present invention. It is not an admission that any of the
information provided herein is prior art or relevant to the presently claimed
invention, or that any publication specifically or implicitly referenced is prior art.
[003] Flange ring manufacturing process is known to have been available in the
market.
[004] The conventional process for manufacturing flange ring for wheel rims
involves the following 9 stages, wherein the stages have to be performed in below
mentioned sequence:
• Hot rolling of profiled bar
• Coiling of said profiled bar
• Band - Sawing of coiled bar
• Tack welding. The tack welding is used as temporary means for holding the
two ends of coiled bar after band sawing operation
• Butt welding. It is performed on the portion of tack welding area
• Trimming. It is used to remove extra welding portion which was generated
during butt welding operation
• Grinding of welding area
• Shrinking of flange ring
• Expansion of flange ring
[005] Thus, the method comprises hot rolling of profiled bar (1) followed by
coiling of profiled bar (2) followed by band-sawing to form circular ring shape (3)
followed by tack welding (4) as temporary means for holding the two ends of coiled
bar after band sawing operation. Further, butt welding (5) is performed on the tack
welding area followed by trimming (6) of butt welding area followed by grinding
(7) of weld area followed by shrinking (8) of flange ring. The shrunk flange ring
(8) is subjected to expansion.
[006] However, the aforesaid prior art is associated with several drawbacks listed
hereinbelow:
• Less control on dimensions of profile bar due to hot rolling process.
• Dimensional variation in hot rolling leads to rejection of profiled bar as well
as rejection in further operation too.
• Less productivity due to more number of operation steps.
• End joining required welding operation which is not good for human being
as well as environment and also more end product rejection due to welding.
[007] Now, reference may be made to the following publications: -
[008] US5857800- An annular shaft flange for attachment to a shaft extending
along a longitudinal axis, the shaft flange comprising: a flange body having a first
axial end face and a second axial end face, the first and second axial end faces being
parallel and opposed, the first and second axial end faces being spaced to define an
axial width of the shaft flange, wherein each of the first and second axial end faces
has a radial width extending between an inner curved surface and an outer curved
surface, the radial width being substantially larger than the axial width of the shaft
flange; a first nest end and a second nest end formed on the flange body, the first
and second nest ends being spaced apart when the annular shaft flange is in an open
position; a hinge channel formed in the flange body to permit the flange body to
flex between the open position and a closed position, the hinge channel extending
radially outward from the inner curved surface a distance less than the radial width
of the flange body; a first lip extending from the first nest end of the flange body,
the first lip having a width of approximately one-half the axial width of the flange
body and being spaced inwardly from the first axial end face by a first recess
approximately equal to one-half the axial width of the flange body; and a second
lip extending from the second nest end of the flange body, the second lip having a
width of approximately one-half the axial width of the flange body and being spaced
inwardly from the second axial end face by a second recess approximately equal to
one-half the axial width of the flange body; wherein when the flange body is flexed
from the open position to the closed position, the first lip is received in the second
recess and overlaps the second lip such that the first and second lips can be spot
welded to retain the shaft flange in the closed position.
[009] US4266417- A process for producing an integral and unitary steel flanged
wheel rim, said process comprising: providing a single steel band, and passing said
steel band longitudinally and successively through a series of shaping rolls and
therein sequentially plastically deforming said steel band to form a longitudinal
wheel rim blank having a cross-sectional configuration including a rim body, a pair
of spaced and parallel hollow ears extending outwardly from a first side of said rim
body at opposite lateral edges thereof, each said hollow ear including a laterally
outer leg portion and a laterally inner leg portion, a pair of beads, each said bead
extending laterally inwardly from a laterally inward portion of a respective said
inner leg portion of a respective said hollow ear, a recess formed in said rim body
laterally centrally thereof between laterally inner ends of said beads, said recess
opening at said first side of said rim body and convexly extending from an opposite
second side of said rim body, and a flange extending from said second side of said
rim body at said convexly extending recess, said flange having a pair of leg
portions; providing a bending machine including presser roll means, outer and inner
feed roll means, said inner feed roll means including a pair of axially spaced rolls
with a space therebetween, said pair of rolls being axially movable toward and away
from each other, and bending roll means; feeding said blank through said bending
machine by rotating said outer and inner feed roll means in contact with said first
and second sides, respectively, of said blank; pressing said presser roll means
against said first side of said blank at a position upstream of said feed roll means,
and pressing said bending roll means against said first side of said blank at a
position downstream of said feed roll means, and thereby bending said blank about
said inner feed roll means as a fulcrum and thus forming said blank into a ringshaped
member with said flange extending radially inwardly; and during said steps
of feeding and bending, axially moving said pair of rolls of said inner feed roll
means together and thereby pressing said leg portions of said flange together and
thus substantially preventing radial compression and corrugation of said flange
during said step of bending.
[010] However, none of the above can fulfill the requirements of the present
invention for which it has been devised.
OBJECTS OF THE INVENTION
[Oil] An object of the invention is to propose a process for manufacturing a flange
ring for wheel rims which obviates shortcomings of prior art.
[012] Another object of the invention is to propose a process for manufacturing a
flange ring for wheel rims which is simple and efficient.
[013] Still another object of the present invention is to provide a process for
manufacturing a flange ring for wheel rims which involves less number of
operation.
[014] Yet another object of the present invention is to provide a process for
manufacturing a flange ring for wheel rims which results in less rejection and better
dimensional control.
[015] Further object of the present invention is to provide a process for
manufacturing a flange ring for wheel rims which has no requirement of welding
and grinding.
[016] Yet further object of the present invention is to provide a process for
manufacturing a flange ring for wheel rims which allows medium and high tensile
hot/cold rolled sheet material to be used.
[017] These and other objects and advantages of the present invention will be
apparent to those skilled in the art after a consideration of the following detailed
description taken in conjunction with the accompanying drawings in which a
preferred form of the present invention is illustrated.
SUMMARY OF THE INVENTION
[018] One or more drawbacks of conventional systems and process are overcome,
and additional advantages are provided through the apparatus and a method as
claimed in the present disclosure. Additional features and advantages are realized
through the technicalities of the present disclosure. Other embodiments and aspects
of the disclosure are described in detail herein and are considered to be part of the
claimed disclosure.
[019] According to this invention, there is provided a process for manufacturing
a flange ring for wheel rims comprising: -
a. blanking of sheet material,
b. drawing/ flow forming of said sheet blank material,
c. piercing of said drawn/ flow formed material to produce one flange ring
and one sheet material blank for disc,
d. expansion and re-striking of said flange ring,
e. machining of said flange ring.
[020] Said blanking of sheet material is carried out with center hole piercing.
[021] Said blanking of sheet material is carried out without center hole piercing.
[022] The expansion and re-striking (13) is carried out so as to form the desired
shape and to increase the inner diameter for optimum machining margin of said
flange ring.
[023] The sheet material includes special grade high tensile steel sheets.
[024] Various objects, features, aspects, and advantages of the inventive subject
matter will become more apparent from the following detailed description of
preferred embodiments, along with the accompanying drawing figures in which
like numerals represent like components.
[025] It is to be understood that the aspects and embodiments of the disclosure
described above may be used in any combination with each other. Several of the
aspects and embodiments may be combined to form a further embodiment of the
disclosure.
[026] The foregoing summary is illustrative only and is not intended to be in any
way limiting. In addition to the illustrative aspects, embodiments, and features
described above, further aspects, embodiments, and features will become apparent
by reference to the drawings and the following detailed description.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
[027] The illustrated embodiments of the subject matter will be best understood
by reference to the drawings, wherein like parts are designated by like numerals
throughout. The following description is intended only by way of example, and
simply illustrates certain selected embodiments of devices, systems, and processes
that are consistent with the subject matter as claimed herein, wherein: -
Figure 1 shows: The flow diagram of the conventional process for
manufacturing flange ring for wheel rims.
Figure 2 shows: The flow diagram of the new process for manufacturing
flange ring for wheel rims in accordance with present
invention.
[028] The figures depict embodiments of the disclosure for purposes of illustration
only. One skilled in the art will readily recognize from the following description
that alternative embodiments of the structures and methods illustrated herein may
be employed without departing from the principles of the disclosure described
herein.
DETAIL DESCRIPTION OF THE PRESENT INVENTION WITH
REFERENCE TO THE ACCOMPANYING DRAWINGS OF PREFERRED
EMBODIMENTS
[029] While the embodiments of the disclosure are subject to various
modifications and alternative forms, specific embodiment thereof have been shown
by way of example in the figures and will be described below. It should be
understood, however, that it is not intended to limit the disclosure to the particular
forms disclosed, but on the contrary, the disclosure is to cover all modifications,
equivalents, and alternative falling within the scope of the disclosure.
[030] The instant invention relates to a technology pertaining to a process for
manufacturing a flange ring for wheel rims.
[031] In order to overcome the above-mentioned problems of the prior art, the
present invention introduces a novel process for manufacturing flange ring.
[032] The proposed invention has improved upon the conventional process. For
the present invention, reference may be made to figure 2.
[033] The process has to be followed in the below mentioned sequence. The steps
of the process are as follows: -
Step 1: Blanking of sheet material with or without center hole piercing
Step 2: Drawing/ flow forming of the said sheet material.
Step 3: Piercing to obtain one flange ring and one blank for disc.
Step 4: Expansion and re-striking of the flange ring
Step 5: Machining of said flange ring.
[034] Thus, the process comprises blanking of sheet material. According to one
embodiment of present invention, said blanking of sheet material is carried out with
center hole piercing (10).
[035] In accordance with another embodiment of present invention, said blanking
of sheet material is conducted without center hole piercing.
[036] Thereafter draw or flow forming (11) is performed on the said sheet blank
material. Further, piercing (12) is done to obtain one flange ring and one sheet
material blank for disc.
[037] Further, expansion and restriking (13) of the flange ring is carried out to
form the desired shape of the said flange ring which is followed by machining (14)
of the said flange ring.
[038] Advantageous features of the present invention are mentioned herein below:
Less number of operation
• Less rejection
• Better dimensional Control
• No requirement of welding and grinding
• Allows use of High tensile material, which is not possible in prior art.
[039] Each of the appended claims defines a separate invention, which for
infringement purposes is recognized as including equivalents to the various
elements or limitations specified in the claims. Depending on the context, all
references below to the "invention" may in some cases refer to certain specific
embodiments only. In other cases, it will be recognized that references to the
"invention" will refer to subject matter recited in one or more, but not necessarily
all, of the claims.
[040] Groupings of alternative elements or embodiments of the invention
disclosed herein are not to be construed as limitations. Each group member can be
referred to and claimed individually or in any combination with other members of
the group or other elements found herein. One or more members of a group can be
included in, or deleted from, a group for reasons of convenience and/or
patentability. When any such inclusion or deletion occurs, the specification is herein
deemed to contain the group as modified thus fulfilling the written description of
all groups used in the appended claims.
[041] It will be understood by those within the art that, in general, terms used
herein, and especially in the appended claims (e.g., bodies of the appended claims)
are generally intended as "open" terms (e.g., the term "including" should be
interpreted as "including but not limited to," the term "having" should be
interpreted as "having at least," the term "includes" should be interpreted as
"includes but is not limited to," etc.). It will be further understood by those within
the art that if a specific number of an introduced claim recitation is intended, such
an intent will be explicitly recited in the claim, and in the absence of such recitation
no such intent is present. For example, as an aid to understanding, the following
appended claims may contain usage of the introductory phrases "at least one" and
"one or more" to introduce claim recitations. However, the use of such phrases
should not be construed to imply that the introduction of a claim recitation by the
indefinite articles "a" or "an" limits any particulars claim containing such
introduced claim recitation to inventions containing only one such recitation, even
when the same claim includes the introductory phrases "one or more" or "at least
one" and indefinite articles such as "a" or "an" (e.g., "a" and/or "an" should
typically be interpreted to mean "at least one" or "one or more"); the same holds
true for the use of definite articles used to introduce claim recitations. In addition,
even if a specific number of an introduced claim recitation is explicitly recited,
those skilled in the art will recognize that such recitation should typically be
interpreted to mean at least the recited number (e.g., the bare recitation of "two
recitations," without other modifiers, typically means at least two recitations, or two
or more recitations). Furthermore, in those instances where a convention analogues
to "at least one of A, B and C, etc." is used, in general such a construction is
intended in the sense one having skill in the art would understand the convention
(e.g., "a system having at least one of A, B and C" would include but not be limited
to systems that have A alone, B alone, C alone, A and B together, A and C together,
B and C together, and/or A, B, and C together, etc.). In those instances where a
convention analogous to "at least one of A, B, or C, etc." is used, in general such a
construction is intended in the sense one having skill in the art would understand
the convention (e.g., "a system having at least one of A, B, or C" would include but
not be limited to systems that have A alone, B alone, C alone, A and B together, A
and C together, B and C together, and/or A, B, and C together, etc.). It will be
further understood by those within the art that virtually any disjunctive word and/or
phrase presenting two or more alternative terms, whether in the description, claims,
or drawings, should be understood to contemplate the possibilities of including one
of the terms, either of the terms, or both terms. For example, the phrase "A or B"
will be understood to include the possibilities of "A" or "B" or "A and B".
[042] The above description does not provide specific details of manufacture or
design of the various components. Those of skill in the art are familiar with such
details, and unless departures from those techniques are set out, techniques, known,
related art or later developed designs and materials should be employed. Those in
the art are capable of choosing suitable manufacturing and design details.
[043] The terminology used herein is for the purpose of describing particular
embodiments only and is not intended to be limiting of the present disclosure. It
will be appreciated that several of the above-disclosed and other features and
frnctions, or alternatives thereof, may be combined into other systems or
applications. Various presently unforeseen or unanticipated alternatives,
modifications, variations, or improvements therein may subsequently be made by
those skilled in the art without departing from the scope of the present disclosure as
encompassed by the following claims.
[044] The claims, as originally presented and as they may be amended, encompass
variations, alternatives, modifications, improvements, equivalents, and substantial
equivalents of the embodiments and teachings disclosed herein, including those that
are presently unforeseen or unappreciated, and that, for example, may arise from
applicants/patentees and others.
[045] While various aspects and embodiments have been disclosed herein, other
aspects and embodiments will be apparent to those skilled in the art. The various
aspects and embodiments disclosed herein are for purposes of illustration and are
not intended to be limiting, with the true scope and spirit being indicated by the
following claims.

WE CLAIM:
1. A process for manufacturing a flange ring for wheel rims comprising:-
a. blanking of sheet material,
b. drawing/ flow forming of said sheet blank material,
c. piercing of said drawn/ flow formed material to produce one flange
ring and one sheet material blank for disc,
d. expansion and re-striking of said flange ring,
e. machining of said flange ring.
2. The process for manufacturing flange ring of wheel rims as claimed in claim
1, wherein said blanking of sheet material is carried out with center hole
piercing.
3. The process for manufacturing flange ring of wheel rims as claimed in claim
1, wherein said blanking of sheet material is carried out without center hole
piercing.
4. The process for manufacturing flange ring of wheel rims as claimed in
claims 1-3, wherein the expansion and re-striking (13) is carried out so as
to form the desired shape and to increase the inner diameter for optimum
machining margin of said flange ring.
5. The process for manufacturing flange ring of wheel rims as claimed in
claims 1-4, wherein the sheet material includes special grade high tensile
steel sheets.