Forging Three-dimensional art of forging
The forging process is an complex, fully automated process. This not only guarantees the precise reproducibility of many thousands of wheels, but is also miles away from the origins of forging, one of mankind's oldest manual processes for producing tools and everyday objects.
Practice and theory combined: the supreme discipline of forged wheel production
In the world of forged wheel production, we are the pioneers who masterfully combine theory and practice. Our expertise extends not only to manual forging and machining, but also to the theoretical side of 3D simulation.
Simulation before production: unique and world-leading
We are the only company in the world that can simulate every single forging step in 3 dimensions to this extent. With our experience, expertise and advanced analysis techniques, we observe exactly how the material behaves during forging.
Precision and predictive power
Through numerical analysis, we simulate and predict the behavior of wheel designs under different conditions. This precision modeling helps us identify potential stress points, optimize material usage and ensure our wheels can withstand the rigors of real-world driving.
Durability and longevity
Our structural analysis, supported by tools such as Finite Element Analysis (FEA), evaluates the effects of various forces on the wheel structure. The result is improved designs that are both lighter and stronger.
We develop wheels that not only meet industry standards, but exceed them. The result: safer, more efficient vehicles and a driving experience that is smoother than ever before.
Focus on production: insights into manufacturing
From a simple Aluminum block to a round wheel
The starting material is a piece of aluminum that is sawn to the desired height. Before the first forging stage, it is homogenized in a continuous furnace and brought to the required temperature.
In the 4,000-tonne press, the connecting piece is then forged into a flat wheel.
The blank is then given the typical design of the future wheel under 7,000 tons of pressing force. The wheel disc is then perforated and trimmed fully automatically under the 800-ton press.
Flow pressing, flow forming, rolling - this step has many names.
And yet it is one of the most exciting steps in the development of a forged wheel. A computer-controlled robot positions the workpiece on the tool. Three hydraulically operated metal rollers with different outer radii then move to the wheel. The horizontal and vertical movement of these rollers is precisely computer-controlled. The metal rollers move against the rotating workpiece, slowly moving up and down across the entire width of the rim, whereby the rim area is rolled wider and wider and takes on its actual shape. This process almost looks like the pottery of a vase.
After rolling, the wheel receives the necessary heat treatment in an oven to ensure a uniform microstructure. It is then abruptly cooled in a water bath and then heat-hardened to achieve the high final strength.
Finishing is carried out at room temperature by turning, drilling and deburring. This is where the holes for wheel bolts, valves and adjustment holes are drilled.
After various cleaning and testing operations, the surface that characterizes a genuine forged FUCHSFELGE is finished.
» Click here for more information on surfaces and tests.
TECH-FACT:
The formability of the material and the heat treatment are decisive for the extraordinary strength of forged wheels compared to cast wheels. Yield strength, tensile strength, flexural fatigue strength and toughness are consistently better with forged wheels. The ductility is even three times higher than that of cast wheels. In addition, forging produces a very fine-grained and homogeneous structure. Our clear recommendation is therefore: Trust forged wheels! Because even if a cake made of sand looks like a real cake - you wouldn't eat it, would you?