For some wheel forgings, if the fillet radius is too large, the metal will be lost prematurely, causing local dissatisfaction. How to choose an appropriate fillet radius and hammer the die wheel forging is particularly important. The main contents of the hammer fillet regarding the fillet radius have been explained in the chapter of tire mold forging, and will not be repeated here.
Punching with skin: When die forging of the wheel forging, it is impossible to get through holes. It can only be forged into non-through holes, leaving a layer of metal in the middle, and then punching it out on a cutting edge press. The thickness of the continuous skin has a great influence on the fullness of the wheel forging, the wear of the mold and the utilization rate of the metal. Therefore, it is necessary to determine the form of continuous skin according to the wheel forging hole size and die cavity selection. Die wheel forgings often use the following four forms of continuous skin and smaller diameter non-through holes.
Ribs and webs: Wheel forgings with ribs and webs can reduce the size of ribs and webs to reduce the weight of wheel forgings while ensuring the strength and rigidity of the wheel forgings. However, if the ribs are narrow and the web is thin, it will be difficult to fill the die cavity with metal, the required forging force will increase sharply, and quality defects will also be prone to occur. Because the surface area per unit volume of the wheel forging is large at this time, the metal flow is subject to large frictional resistance, and the temperature of the wheel forging is also easy to decrease. Therefore, the dimensions of ribs and webs cannot be too small, and they should be restricted based on the requirements of swaging.
Structural analysis of wheel forgings: When designing wheel forgings, if the wheel forgings have various structural forms, they should be compared, and the easy to form and low cost solutions should be selected from them.