Seeking for a light wheel, VOX contacted OTTO FUCHS. Please click here to watch the VOX TV-report.
Forged, not cast!
The Forging Process
Forging - a complex process, which must provide the maximum in safety. In a series of steps, the wheel is prepared for its important task for a long automotive life.
Step 1: The cast bar
A cast block also produced by OTTO FUCHS of over 6 m in length is the starting material from which a blank is sawn off, exactly matching the later wheel.
Step 2: The pre-forging
In the first forging stage, the blank is forged into a rotationally symmetric piece under a force of 4,000 tonnes.
Step 3: The styling forging
In the second forming stage, the styling is pressed into the pre-forged blank in a 7,000 tonnes press, which largely gives the wheel its later appearance.
Step 4: The clipping
In the last forging stage with 800 tonnes of press force, the ventilation holes and the hub are stamped out, and the burring of excess material around the circumference cut off.
Step 5: The flow-forming
The outer edge of the wheel is heated. The complete rim area, from the outer to the inner flange, is rolled out - which is exactly what goes to make a Fuchsfelge®.
Step 6: The finishing
The finishing takes place in the last step: turning, drilling and deburring. The complex process is rounded off by painting.