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Lack of knowledge about the flow-forming process to wheel rim applications, and the expected results as a function of the material properties and process conditions, is a restriction to extending the use of high-strength steel with this technology to the wheel rim of new generations. The focus of this project was to increase knowledge of flow-forming behaviour of high-strength steel when applied to wheel rims, and to develop reliable numerical tools useful for both flow-forming and fatigue-life estimation, allowing for the study of the performance at the early design stage. The main subjects and results of the research project were as follows. 1. A DOE plan was defined and flow-formed rims were produced with the selected materials and different sets of process parameters (thinning, advance speed and rotational speed). 2. The results from the production campaign were extracted, contributing to greater knowledge about steels and the production process. 3. A wide campaign of testing at laboratory level on flow-formed material led to greater knowledge of the process and established differences among the various materials studied. 4. Specific knowledge has been gained on the fatigue-life of the final material as a function of the process conditions. 5. Regarding numerical analyses, FE models of the flow-forming process were developed with very effective results in assessing the material flow during the process and final plastic deformation. 6. A methodology for fatigue-life prediction of the flow-formed wheel rim was developed and implemented in a commercial code. The validation of the methodology was carried out using an industrial study.

Additional information

Authors: NOTARGIACOMO S, Centro Sviluppo Materiali SpA (CSM), Roma (IT);PLACIDI F, Centro Sviluppo Materiali SpA (CSM), Roma (IT);REYNAERT A, Automotive Application Research Center (Arcelor), Montataire (FR);DUCHET M, ArcelorMittal Research, Maizières-lès-Metz (FR);VALENTE F, Magnetto Wheels SPA, Rivoli (IT);SANTOS M, Fundation Labein, Derio Bizkaia (ES);PÉREZ I, Fundation Labein, Derio Bizkaia (ES)
Bibliographic Reference: EUR 23726 EN (2009), 160 pp. Euro: 20
Availability: (Catalogue Number: KI-NA-23726-EN-S)
ISBN: ISBN: 978-92-79-10858-7
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