Generally speaking, everyone knows about casting. To put it simply, it is the technology of pouring molten aluminum into a mold for cooling and forming. So what is the difference between forging and it? Why is the price higher than that of cast forged wheels, which are increasingly used by modification enthusiasts as the first choice for wheel replacement? Today we will talk about the wheel manufacturing process-forging.
If you compare the molding method of a cast wheel to a popsicle: pour sugar water into a mold to cool it into various shapes, then forging a wheel is to build a sword. There is an idiom that can describe its quality well: it is made into steel. The craftsman beats the blank with one hammer and one hammer to expel the impurities inside. Thousands of strikes make a sharp sword. Just returning to the wheel manufacturing, it is the forging press of tens of thousands of tons to "sing the final word."
Forging is a processing method that uses forging machinery to apply pressure to metal blanks to produce plastic deformation to obtain forgings with certain mechanical properties, certain shapes and sizes. It is one of the two major components of forging (forging and stamping).
Advantages of forging
Through forging, the as-cast looseness of metal and welding holes can be eliminated, and the mechanical properties of forgings are generally better than those of castings of the same material. For the important parts of machinery with high load and severe working conditions, forgings are mostly used except for simpler shapes that can be rolled, profiles or welded parts.
Forging can be divided into milling and die forging
1. Milling and forging
Use impact or pressure to deform the metal between the upper and lower anvils (anvils) to obtain the required block blanks. The cakes are heat-treated and then milled through the machining center to form them, but because the cakes are thick and inconsistent The poor hardenability during the heat treatment may result in the material properties of the final product may not reach the forging process quality level. In addition, the forging flow line will be cut off during the machining and forming process, resulting in the final shape of the wheel product cannot be truly lightweight.
2. Die forging
Die forging is divided into open die forging and closed die forging. The metal blank is compressed and deformed in a forging die with a certain shape to obtain forgings. Because the forgings produced under this process are formed in the shape of the die at one time, the product wall thickness is uniform, and the performance after heat treatment reaches the best performance, so the die-forged wheel The best quality and the lightest weight. Of course, the die forging process requires a series of special molding dies, so its products are expensive.
Forged wheels are currently the most advanced method of manufacturing aluminum wheels. Its most prominent advantages are high strength, higher safety, strong plasticity, light weight, good heat dissipation, and fuel saving; the disadvantage is that the price is slightly higher and the production cycle is longer. , So what are the advantages of forged wheels compared to original cast wheels?
1. Rugged and safer
Forged aluminum rings are 1-2 times stronger than cast aluminum rings and 4-5 times that of general iron rings. Therefore, they are stronger and more resistant to collisions, and their toughness and fatigue strength are significantly better than those of cast wheels. They are not easy to crush and break and are more safe. Strong.
2. Lightweight and more fuel-efficient
Compared with casting, a forged wheel of the same size can be about 20% lighter in weight, and 1KG lighter on the wheel can increase 10 horsepower. In addition, the light weight also makes the suspension response speed significantly improved, the suspension system has a faster response speed, and it is naturally easier to deal with potholes on the road.
3. Fuel saving and good heat dissipation performance
According to Japanese experiments, every 1kg reduction in the weight of a 5-seater car will save about 20L of gasoline a year. A research report published by the American Society of Automotive Engineers pointed out that although forged wheels are more expensive than ordinary cast wheels, in the long run, cars will reach The cost can be recovered within 30,000 kilometers. In addition, the forged wheels have better heat dissipation effect, which can prevent the brake drum and tires from aging during long-distance high-speed driving, increase the life span, and reduce the risk of tire blowouts.
4. Better control performance
Upgrade the forged wheels without affecting the steering and loading. If the width of the wheels is increased, the sensitivity of the vehicle in acceleration, braking and corners will be significantly improved, whether it is from a standstill to a starting point, or accelerating during driving. Brisk, the vehicle will be comfortable regardless of whether it is entering or exiting a bend.
To sum up, forged wheels are superior to casting in terms of performance and quality, and the improvement in vehicle performance is significant, but the price is also visible to the naked eye compared to casting, so it is still necessary to make corresponding choices according to personal needs . It should be noted that when choosing a forged wheel, you must pay attention to the wheel brand, otherwise the purchase of some niche brands of "forged" wheels is likely to lead to a "breaking" tragedy, and safety issues should not be taken lightly.
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