Method for Producing a Cast Vehicle Wheel

Abstract

A method for producing a one-piece cast vehicle wheel, the wheel having at least one hub portion connected to a wheel rim via at least one spoke oriented in the radial direction of the wheel, in which at least one lost core is inserted in a molding of the casting machine, the one-piece vehicle wheel is cast, and the lost core is removed from the cast vehicle wheel and thereby forms at least one opening in the spoke. A one-piece cast vehicle wheel formed by the method is also provided.

Claims

1-14. (canceled)

15. A method for producing a one-piece cast vehicle wheel having a hub section connected to a rim via at least one spoke oriented in a radial direction of the wheel, comprising the acts of: inserting at least one lost core into a mold of a casting machine; casting the one-piece cast vehicle wheel; and removing the at least one lost core from the cast vehicle wheel, where after removal of the at least one lost core at least one opening is present in the at least one spoke where the at least one core was located during casting.

16. The method according to claim 15, wherein the at least one opening is formed on at least one spoke side surface of the at least one spoke, the at least one spoke side surface being aligned at least approximately in an axial direction of the wheel.

17. The method according to claim 15, wherein the at least one lost core is formed by a core shooting method or a 3D printing method.

18. The method according to claim 15, wherein, after the casting the at least one spoke of the vehicle wheel is one or more of machined, blasted and trowalized.

19. The method according to claim 15, wherein a part of a spoke surface of the at least one spoke what which no opening is present after removal of the at least one core is mechanically processed such that an additional opening is formed which opens in the at least one opening formed by the at least one lost core.

20. The method according to claim 15, wherein after removal of the at least one lost core the at least one opening is configured to receive a cover element.

21. The method according to claim 20, wherein the cover element is configured to cover one or both of a spoke intermediate space and a wheel cap.

22. The method according to claim 16, wherein after removal of the at least one lost core the at least one opening includes at least one opening on one or both of a spoke outer surface and a spoke inner surface.

23. A vehicle wheel, comprising: a one-piece wheel having a hub section, a rim and in a radial direction of the wheel, wherein the one piece wheel is formed by inserting at least one lost core into a mold of a casting machine, casting the one-piece cast vehicle wheel, and removing the at least one lost core from the cast vehicle wheel, and after removal of the at least one lost core at least one opening is present in the at least one spoke where the at least one core was located during casting.

24. The vehicle wheel according to claim 23, wherein the at least one opening is one or more of a recess, an undercut and aperture arranged on a spoke side surface of the at least one spoke.

25. The vehicle wheel according to claim 23, wherein the at least one lost core protrudes through the at least one spoke after the casting process of the vehicle wheel and before removal of the at least one lost core in a circumferential direction of the vehicle wheel.

26. The vehicle wheel according to claim 25, wherein the at least one spoke includes at least two spokes, and after casting and before removal of the at least one lost core, the at least one lost core is arranged in mutually facing spoke side surfaces of the at least two adjacent spokes and protrudes into at least two spoke intermediate spaces.

27. The vehicle wheel according to claim 23, wherein the at least one lost core is formed with at least a portion which is ring-shaped.

28. The vehicle wheel according to claim 23, wherein after removal of the at least one lost core the at least one opening is configured to receive a cover element.

29. The vehicle wheel according to claim 28, further comprising: a cover element is configured to cover one or both of a spoke intermediate space and a wheel cap.

30. The vehicle wheel according to claim 23, wherein after removal of the at least one lost core the at least one opening includes at least one opening on one or both of a spoke outer surface and a spoke inner surface.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0044] FIG. 1 shows schematically a vehicle wheel according to an embodiment of the present invention in a three-dimensional view from the front.

[0045] FIG. 2 shows a detailed view of part of the vehicle wheel of FIG. 1 from the front, wherein a lost core is illustrated before removal from the cast vehicle wheel.

[0046] FIG. 3 shows a detailed view of part of a vehicle wheel of FIG. 1 from the front, wherein a lost core is illustrated before removal from the cast vehicle wheel.

[0047] FIGS. 4 to 7 each show examples of a vehicle wheel in a front view, wherein a lost core is illustrated in different embodiments before removal from the cast vehicle wheel.

[0048] FIG. 8 shows a vehicle spoke in a sectional view through an axis of rotation of the wheel in accordance with an embodiment of the present invention, the vehicle spoke just being cast.

[0049] FIG. 9 shows a spoke of a ready cast vehicle wheel in accordance with an embodiment of the present invention from the rear, in which spoke connecting elements engage.

DETAILED DESCRIPTION OF THE DRAWINGS

[0050] As illustrated in the exemplary embodiment in FIG. 1, a vehicle wheel produced according to the method according to the invention comprises a hub section 1 which is connected to a rim or a rim section 4 via a plurality of spokes 2 which are oriented in the radial direction of the wheel. Furthermore, the vehicle wheel shows a plurality of spoke intermediate spaces 3 arranged between two adjacent spokes 2. The wheel, i.e. with the rim 4 mentioned, the spokes 2 and the hub section 1, is cast in one piece as a whole. Furthermore, it is provided that the spokes 2 includes a plurality of apertures 5 and recesses 6 by removal of a lost core 7 after the process of casting the one-piece vehicle wheel.

[0051] Such an opening can be realized, for example, by an aperture 5 through the entire spoke material or as a recess 6 (can also be referred to as an undercut stamping) or as a groove in a spoke 2.

[0052] It is possible here, as can likewise be seen in FIG. 1, that such an aperture 5 or such a recess 6 is arranged on a spoke side surface 2.1 or on a spoke outer surface 2.2.1 (or on a spoke inner surface 2.2.2). Within the context of this invention, such a spoke outer surface 2.2.1 is that surface of the spoke 2 which, in the installed state of the vehicle wheel in the vehicle, faces away from the vehicle and is oriented at least approximately in the axial direction A of the vehicle wheel. Within the context of this invention, a spoke inner surface 2.2.2 means that surface of the vehicle wheel which, in the installed state of the vehicle wheel in the vehicle, faces the vehicle and is likewise oriented at least approximately in the axial direction A of the vehicle wheel. The spoke side surfaces 2.1 are those spoke surfaces which are oriented in the circumferential direction of the wheel and form, inter alia, the spoke intermediate space 3.

[0053] In order to realize a wheel which is cast in one piece and has such undercuts or recesses 6 or apertures 5, it is provided that the wheel is produced in a casting method. It is furthermore provided, as can be seen by way of example in FIG. 2, that, before the process of casting the wheel, what is referred to as the lost core 7 is inserted into the molding of the casting machine. The wheel is then cast in one piece with the lost core. After the casting process, the lost core 7 is still situated in the vehicle wheel, as shown by way of example in FIG. 2. For example, the lost core can be designed as a section of a ring in the circumferential direction of the wheel. By subsequent removal of the lost core 7, for example by shaking it out or by vibration, the aperture 5 mentioned or the recess 6 mentioned or the undercut is formed. FIG. 2 shows the lost core 7 still situated in a first spoke 2 after the casting process. The aperture 5 which is formed when the lost core 7 is removed from the wheel or from the spoke 2 is shown in a further spoke 2 in FIG. 2. Using an annular lost core 7 (as illustrated by the dashed line in FIG. 2) which extends in a closed manner about a circumference of a circular portion of the wheel, such an aperture 5 or a recess 6 can be formed at always the same location on each spoke 2 of the wheel. However, it is also possible to arrange a plurality of individual lost cores 7.

[0054] The lost core 7 from FIG. 2 is arranged at least approximately in the circumferential direction of the wheel, wherein the aperture 5 or the recess 6 which is formed by removal of the lost core 7 is arranged on a spoke side surface 2.1. It is alternatively or additionally also possible, as can be seen in FIG. 3, to orient the lost core in the axial direction A of the vehicle wheel and thus to form or to arrange an aperture 5 or a recess 6 on the spoke outer surface 2.2.1 or on the spoke inner surface 2.2.2 after removal of the lost core 7. FIG. 3 also shows a first spoke 2 in an outer view of the wheel, in which the lost core 7 is still arranged in the spoke 2, and a second spoke 2, in which the lost core 7 has already been removed and an aperture 5 thereby being formed.

[0055] FIGS. 4 to 7 each show different embodiments or geometries of one or more lost cores 7 in a ready cast vehicle wheel.

[0056] As shown in FIG. 4, the lost core 7 can be designed as a continuous annular body which is capable upon removal of forming a plurality of apertures 5 or recesses 6 per spoke 2 of the wheel.

[0057] As illustrated in FIG. 5, it is also possible to form an annular lost core 7 by a plurality of lost cores 7 that are adjacent next to one another and are in the shape of a section of a ring being arranged only on a certain radius of the wheel (for example only in the vicinity of the hub).

[0058] Similarly, as shown in FIG. 6, an (at least approximately) annular lost core 7 can be arranged on an outer radius of the wheel, i.e. in the direct vicinity of the rim, in a manner extending over the circumference of the wheel, and therefore, when the lost core is removed, an aperture 5 is formed on such an outer radius of the wheel on all of the spokes 2 of the wheel. FIG. 7 shows an embodiment in which the aperture 5 on the respective spokes 2 is not formed by a cohesive annular lost core 7 (as in FIG. 6), but rather by individual lost cores 7 in the shape of a section of a ring.

[0059] By means of the arrangement of such a lost core, any conceivable geometric configuration of a spoke 2 is possible. For example, by means of a suitable arrangement of a lost core 7 and by means of the removal of the lost core 7 after the casting process, two spokes 2 which are offset with respect to one another in the axial direction A are formed.

[0060] It is likewise possible for the lost core 7 to be divided into two, as viewed in the axial direction A of the wheel. For example, the two parts can then be connected by a suitable adhesive. Furthermore, it is possible to produce a complex structure of the lost core 7 by producing the lost core 7 in an additive production method, such as a 3D printing method.

[0061] It is possible by means of such complex geometries of one or more lost cores 7 for the entire spoke geometry/design to be able to be produced exclusively by the lost core 7.

[0062] FIG. 8 shows, by way of example, the casting process of a spoke 2 with a lost core 7, which is inserted into a molding (not shown) of a casting machine, in a sectional view through the axial axis A of the wheel. The melt flow is illustrated here in the form of arrows. It is apparent here how the liquid melt flows from the hub 1 of the wheel as far as the rim 4 of the wheel. The melt fully flows over the lost core 7. After the melt has subsequently hardened and the wheel cast in one piece removed from the molding, the lost core 7 can be removed from the wheel, with the aperture 5 mentioned or the recess 6 arising in the spoke 2.

[0063] It is furthermore possible, as illustrated in FIG. 9, for the apertures 5 mentioned to be formed on the spoke side surface 2.1 by removal of the lost core 7 while an opening 5 is introduced on the spoke inner surface 2.2.2 by subsequent machining. However, it is alternatively also possible to form this opening 5 on the spoke inner surface 2.2.2 likewise by removal of the lost core 7.

[0064] It is in general possible for the ready cast wheel to be further processed mechanically, for example machined, after the casting process.

[0065] Furthermore, it is possible here, as can likewise be seen in FIG. 9, for the openings 5 on the spoke inner surface 2.2.2 and on the spoke side surfaces 2.1 to constitute a fastening device, by means of which fastening device cover elements 8 or other components to be fastened to the spoke 2 can be fastened to or arranged on the spoke 2. Such a cover element 8 can be, for example, an element which is used for at least partially covering the spoke intermediate space 3.

LIST OF REFERENCE SIGNS

[0066] 1 hub section [0067] 2 spoke [0068] 2.1 spoke side surface [0069] 2.2.1 spoke outer surface [0070] 2.2.2 spoke inner surface [0071] 3 spoke intermediate space [0072] 4 rim [0073] 5 opening [0074] 6 recess [0075] 7 lost cores [0076] 8 cover element [0077] A axial direction/axis of rotation