Alloy Wheel Moulding Process
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Design
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Alloy wheel molding begins with the design of the wheel. Using a CAD (computer aided drafting) program, a designer works from an initial program or artwork to carefully lay out the dimensions and design of the wheel in an engineering drawing. This drawing includes the dimensions of the rim, width, height of the rim bead and layout of the spokes. A machinist creates the final cast for the mold from this drawing.
Cast Creation
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A cast mold for each alloy wheel is built. This cast is a mirror-image of the final wheel. It is shaped to contain the alloy materials that are used to create the final product. For instance, if the alloy wheel includes large fin-shaped spokes, the cast will be shaped like a large bucket with thin blades that will fall between these spokes. The inside walls of the cast form the top of the rim where the tire is attached. An indentation along the top of the cast forms the lip bead of the tire rim.
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Molding Process
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Fast-forward to the molding processing facility. Here, the cast is set and filled with the alloy material to create the wheel. In this process the cast is coated with a release compound that reacts with the alloy poured into the mold. After it cools, this compound allows for a quick release of the wheel from the mold. The alloys are injected into the cast form after being heated to their melting point. After casting, the molds are set out to dry and then released from the final product. Molds are reused each time producing several alloy wheels. Different types of alloys are employed in the casting process including carbon and metal, ceramic and metal and steel combination aluminum alloys.
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