1. Conventional forging method
Forging is one of the earliest forming processes for aluminum wheel hubs. Forged aluminum wheels have the advantages of high strength, good corrosion resistance, precise size, and small processing volume. Generally, their weight is only half or less of steel wheels of the same size. The grain flow direction of forged aluminum wheels is consistent with the direction of stress, and their strength, toughness, and fatigue strength are significantly better than those of cast aluminum wheels. At the same time, the performance has good reproducibility, with almost every wheel hub having the same mechanical properties. The typical elongation rate of forged aluminum wheels is 12% -17%, which can effectively absorb road vibrations and stresses. SuKeZhong aluminum alloy forging indicates that usually cast wheels have a relatively strong ability to withstand compressive forces, but their ability to withstand impact, shear, and tensile loads is far inferior to forged aluminum wheels. Forged wheels have a higher strength to weight ratio. In addition, the forged aluminum wheel hub has no air holes on its surface, making it highly capable of surface treatment. This not only ensures uniform and consistent coating, reliable bonding, but also good color. The biggest disadvantage of forging aluminum wheels is that there are multiple production processes and the production cost is much higher than that of casting.
2. Casting and forging method
In response to the problems of multiple conventional forging processes and high costs, a composite forming technology called casting forging has emerged in recent years. It uses castings as raw materials for forging processes and performs plastic deformation on them. The forging of Sukezhong aluminum alloy indicates that by using forging as the final forming process of the part, casting defects can be eliminated, the microstructure of the product can be improved, and the mechanical properties of the product can be greatly improved compared to castings. At the same time, the advantages of casting technology in forming complex parts are fully utilized, reducing the forging process of products with complex shapes, greatly improving material utilization, and reducing production costs. By using casting and forging technology to produce aluminum wheel hubs, their performance can fully meet the mechanical performance indicators of forgings, but the production cost can be reduced by 30% compared to ordinary forged parts. At present, this process has been successfully applied to mass production since September 1996 and has been adopted by multiple Japanese companies with good economic results. Although there have been some studies and applications in the field of casting and forging forming technology in China, there have been no reports on its application in the production of aluminum wheel hubs.
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