FOCUS ON FLOW-FORMING
The FFM machine uses the backward flow-forming process to form weight-optimised rim rings .
STRONG
“ We outline the flow-forming machines and processes for weight-optimised wheels .”
LIGHTWEIGHTS
Arrangement of the rollers .
Less weight means fewer CO 2 emissions for cars and trucks . Flow-forming enables the chipless production of weight-optimised wheels , without loss of payload .
“
With our machines and technology , we can design steel rims for cars and trucks so that they are significantly lighter than conventional wheels and yet just as strong ,” explained Benedikt Nillies , technical director of Leifeld Metal Spinning GmbH in Ahlen in Germany . The company develops machinetools for chipless metal forming , which are used worldwide in the automotive industry ; aerospace technology ; the energy industry and in various consumer and industrial goods sectors .
“ One of our customers was able to use our technology to produce rims with a payload of 580kg , which is almost 900 grams lighter than with other manufacturing processes ,” he explained . This pays off , especially in terms of fuel consumption . The more wheels that are used , the better the result . He cited the example of a tractor unit with six wheels , plus spare wheels and trailer wheels .
So why don ’ t manufacturers go straight for aluminium wheel rims ? After all , he told ISMR , they are much prettier than their steel alternatives and are popular with car buyers when they have been painted , mirror-finished , matt brushed and sometimes chrome-plated . But , he added , they are also more expensive and more vulnerable e . g . to road salt or impact . Repair can also be costly and / or sometimes impossible .
“ Steel rims are much more resilient and , with the right manufacturing process , can actually be even lighter in the car sector ,”
Nillies described . This is different from the truck sector . But here , too , weight savings can be attractive to truck manufacturers and buyers who are less concerned with design and more with economy .
If aluminium rims are often cast or forged in one piece , steel rims
Left : Benedikt Nillies , Technical Director , Leifeld .
46 | sheetmetalplus . com | ISMR June 2021