The wheel forging process is a complex and precise manufacturing procedure, where each step plays a crucial role in determining the final product's quality. This article will provide a detailed overview of the various stages involved in wheel forging, from initial design to the final product.

Initial Design and Blank Design

The first step in wheel forging is drafting the wheel forging diagram and designing the dimensions and shapes of the blanks for each step. This process typically involves comparing similar wheel forgings, performing basic volume calculations, and relying on the experience of skilled designers. However, for complex shapes with multiple steps, the metal flow during deformation cannot be accurately predicted based solely on experience. Therefore, during the trial production of new products, adjustments and modifications are often necessary.

Establishing Design Principles

After the blank design is finalized, the next step is to establish the fundamental design principles for the forging. The process specifications must not only ensure the quality of machining but also meet the technical requirements specified in the client's drawings. Additionally, the process should have high production efficiency to ensure timely delivery of products. Designers must also consider how to reduce manufacturing costs, ease workers' labor intensity, and ensure the safety of the entire production process.

Thermal Expansion and Diagram Adjustments

In the drafting of the wheel forging diagram, calculations typically involve multiplying the cold wheel forging diagram by a thermal expansion coefficient to determine the dimensions of each part. However, in precision wheel forging, different parts may have significantly varying dimensions, causing smaller parts to cool more quickly. This results in a noticeable difference in the final forging temperatures between smaller and larger parts. To address this issue, designers can use different thermal expansion coefficients for different parts based on their specific conditions, ensuring that each part achieves the desired forging effect.

Determining Process Steps

Once all design principles and diagram adjustments are completed, the next step is to determine the specific process steps. This includes analyzing and studying the wheel forging assembly diagram, determining the shape and size of the blank, drafting the production process route, selecting the positioning reference surface, and determining the equipment, tools, fixtures, gauges, and auxiliary tools required for each process. The technical requirements and inspection methods for each major process must also be clearly defined to ensure that the product meets the expected quality standards at every stage. Additionally, it is essential to establish the machining allowance for each process, calculate process dimensions and tolerances, determine cutting parameters, and set reasonable time standards for each process.

Material Selection and Control of Forging Ratio

In terms of material selection, wheel forging typically uses various types of carbon steel and alloy steel, as well as aluminum, magnesium, copper, titanium, and their alloys. The original state of the materials can be bar stock, ingots, metal powder, or molten metal. During the forging process, the ratio of the metal's cross-sectional area before deformation to that after deformation is known as the forging ratio. Proper selection of the forging ratio, reasonable heating temperature and holding time, appropriate starting and final forging temperatures, and suitable deformation amount and speed are crucial to improving product quality and reducing production costs.

Conclusion

Wheel forging is a complex process that requires a high level of expertise and extensive experience. From design to final product, every stage must be precisely controlled to produce wheel products that meet quality standards. As technology continues to advance, the wheel forging process is continually optimized to meet the market's demands for high-quality, efficient production.