ASSIGNMENT

FAKULTI TEKNOLOGI KEJURUTERAAN

MEKANIKAL DAN PEMBUATAN
UNIVERSITI TEKNIKAL MALAYSIA MELAKA
MACHINE TOOL TECHONOLOGY
BMMM 2323

ASSIGMENT

GROUP
ASSIGMENT

LECTURER’S NAME MOHAMAD BIN MINHAT

 

STUDENT’S NAME MATRIX NO:

S1. AHMAD NAQIUDDIN ARIF BIN MOHD FAZIL B092010218
S2. MOHD SYAFIQ BIN ALI AHMAD B092010154

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 TABLE OF CONTENT

Table of Content Page

AUTOCAD DRAWING AND PRODUCT SPECIFICATION

3

INTRODUCTION AND HISTORY 4

PRODUCTION OF CAR RIMS 5-8

APPLICATION OF CAR RIMS 9

REFERENCE 10

2. AUTOCAD DRAWING AND PRODUCT SPECIFICATION

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 AUTOCAD DRAWING

PRODUCT SPECIFICATION

Technology Forged Aluminum Wheel 6061 T6

Size 16 - 22

Width 8J – 12 J

Holes 3,4,5,6

PCD ( mm ) 100 mm, 108 mm, 112 mm, 114.3 mm, 120 mm

ET ( mm ) 100 mm, 108 mm, 112 mm, 114.3 mm, 120 mm

CB ( mm ) 100 mm, 108 mm, 112 mm, 114.3 mm, 120 mm

Finish Brushed , Gloss , Matte , Polished , Machined

3. INTRODUCTION AND HISTORY

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 The first light – alloy sheet aluminium car wheels were used in Daimler – Benz and Auto – Union
racing cars in the 1930 s. In the 1960 s, Porsche began the batch production of sheet wheels, which
consisted of a wheel rim and nave. The first high – volume production of sheet wheels in Europe
started in 1979 for Daimler – Benz cars destined for the USA. Through further development of the
production process for wheel rims and naves, the manufacturing costs were reduced markedly so that
an aluminium sheet wheel has been produced in large numbers for the BMW 5 Series since 1995.

Using aluminium wheels on passenger cars began with the upper class or flagships models in order
to give them a distinctive personal touch. Mainly cast at this time, they started in the 1970s to be
factory – fitted to mass – produced cars. Wheels are now representing about 15% of the average
aluminium content in passenger cars and light trucks, and if the main motivation has been styling
with mainly cast solution, weight reduction requirement have lead to the development of more
technical cast but also forged and fabricated solutions. However, these components have critical
safety functions and must meet high standards of design, engineering and workmanship.

4. PRODUCTION OF CAR RIMS

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 A standard automotive aluminium wheel rim is made from aluminium bar. The aluminium bar is
bent to produce a cylindrical sleeve, and then the two free edges of the sleeve are welded together. At
least one cylindrical flow spinning operation is carried out to obtain the desired thickness profile of
the sleeve—and the desired angle of inclination relative to the axial direction in the zone for the
outer seat. The sleeve is then shaped to obtain the rims on each side with a radially inner cylindrical
wall in the zone of the outer seat and with a radially outer frustonical wall inclined at an angle
corresponding to the standard inclination of the rim seats. The rim is then calibrated. One-piece rim
and wheel assemblies (refer Figure 1 ) may be obtained by Milling and Turning process.

( Figu
re 1 )

RAW MATERIAL ( ALUMINIUM BAR ) PREPARATION

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 Cutting Process

The first process of making car rims is cutting

aluminium bar by using automated cutting saw
machine. The length of aluminium bar is depend
on customer demand

First Forging

Next process is forging a shapes of aluminium bar

with force or compression. A wheel frame is
forged multiple times to achieve the final shape.
When the final shape is made, machining
smooths and buffs the wheel.

Final Forging

This process is similar to the above except the

aluminum is run between heavy stamps or
wheels. The pressure from the rolling forces the
raw material into the shape and thickness
needed.

Punching Process

The purpose of this process is to create a hole in

the middle of wheel frame by using automated
punching machine

MACHINING

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 Spining Process
This process stretches and compresses the
aluminum, which increases tensile strength. The
final product is lighter, stronger, has increased
elongation, and a much greater shock resistance
as well as the ability to increase load capacity
over a traditional cast wheel (of the same design)

Heat treatment
This process improve wheel rims performance,
mechanical properties, precise dimensions, and
shape.

CNC Machining
This process of machining is to give a profile to
car wheel rims by using various machining
method such as milling, turning, lathing and many
more. A complex of machining tool points are
also required to cut precision parts in the wheel
rims.

Lettering Process
After machining process doned, the wheel car
rims are transfer to lettering assembly line to add
company trademarks on the wheels.

FINISHING, QUALITY INSPECTION AND PACKAGING

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 Polished and Painting Process

After the lettering process is complete, next

process is to polished and painting the wheel car
rims.

Quality Inspection

After the finishing process complete, the worker

will check the wheel car rims for it defect.

Packaging

The last step of this process is to packing the

wheel car rims into a box and shipped it to the
customer by airplane, cargo ships and postage
courier.

5. APPLICATION OF CAR RIMS

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Tire rims hold the rubber tire in place so that the vehicle can function. With so many sizes and
styles available, you may wonder what the difference is, how rims work, and if the differences
matter.

Rims are also known as wheels and are necessary for all automobiles, from passenger cars to
commercial vehicles. Wheels provide two uses: they reduce friction and they provide leverage.
The rim is an important part of the wheel because it rotates around rods that are called axles.
Some friction is necessary to turn the wheels, and that is provided by the tire contacting the
pavement. This helps the vehicle move along. The rim magnifies the amount of force applied,
which provides the leverage. The amount of leverage depends on how large the wheel or rim is.
This impacts performance for your vehicle.

Many people focus on rims because of their aesthetic appearance. Change out the style or size of
rims and you can create a new look. Bigger rims may make a vehicle appear more muscular or
sportier while smaller rims create a low profile look.

Rims do more than just make your vehicle look good ( refer Figure 2 ). A good set of car rims
enhance your vehicle’s performance and provide a smoother ride. Changing the size of the rims
on your vehicle impacts the alignment, handling, braking, and acceleration as well as the
calibration of the speedometer.

( Figure 2 )

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6. REFFRENCE

BY BOOK

1) Jazar R.N. (2008) Tire and Rim Fundamentals. In: Vehicle Dynamics: Theory and Application.
Springer, Boston, MA. https://doi.org/10.1007/978-0-387-74244-1_1
2) Jin, J., Wang, X. & Li, L. A sheet blank rotary forging process for disk-like parts with thickened
rims. J Mech Sci Technol 30, 2723–2729 (2016). https://doi.org/10.1007/s12206-016-0534-6
3) Ilyukovich, B.M., Merkur'ev, S.E. Rolling of 6.OB-20B1 lightweight special profile for GAZ-53
car wheel rims. Metallurgist 9, 211–212 (1965). https://doi.org/10.1007/BF00742550
4) Hutcheon K.F., Hawkyard J.B. (1984) Production of Jointless Light Alloy Cycle Wheel Rims
by Ring Rolling. In: Davies B.J. (eds) Proceedings of the Twenty-Fourth International
Machine Tool Design and Research Conference. Palgrave, London.
https://doi.org/10.1007/978-1-349-81247-9_2

BY JOURNAL

1) Waschull S, Bokhorst JAC, Molleman E et al (2020) Work design in future industrial production:
transforming towards cyber-physical systems. Comput Ind Eng. 139:105679
2) H. Akbulut “On optimization of a car rim using nite element method” Finite Elements in
Analysis and Design 39 (2003) 433–443: Elsevier Ltd.
3) Sunil Kumar Nakka et al. “Structural Analysis of Car alloy wheel using Aluminum and
magnesium Alloys” International Journal for Development of Computer Science and
Technology (IJDCST) Issue- V-4, I-2, SW-09, March 2016.
4) B Raghupathi et al. “Design and analysis of car wheel rim using fem technique” International
Journal of Computer Science information and Engg Technologies (IJCSIET) Vol. 3, Series 4,
Issue. 4, Dec. 2014.
5) M.M. Topaç et al. “Fatigue life prediction of a heavy vehicle steel wheel under radial loads by
using finite element analysis” Engineering Failure Analysis 20 (2012) 67–79: Elsevier Ltd.

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