In diesem Video zeigen wir dir Schritt für Schritt, wie Rays Engineering die legendären TE37 Schmiederäder herstellt. Vom Aluminiumrohling bis zum fertigen Leichtbau-Rad – hier steckt mehr Technologie, Präzision und Handarbeit drin, als man denkt.
😇 Dein Abo hilft uns: https://tublo.eu/abonnieren
✅ Source: RAYS WHEELS
➡️ Mehr Infos: https://www.tuningblog.eu/tipps_tuev-dekra-u-co/rays-te37-produktion-764437/
Die TE37 von Rays sind echte Ikonen im Tuning- und Motorsportbereich – ultraleicht, superstabil und mit einem Herstellungsprozess, der seinesgleichen sucht. Du bekommst hier exklusive Einblicke in die aufwändige Schmiedetechnologie, das Design-Finishing und die kompromisslose Qualitätssicherung. Ideal für Performance-Fans, Technik-Nerds und alle, die wissen wollen, was ihre Felgen wirklich können.
#RaysEngineering #TE37 #ForgedWheels #JDM
#Schmiederad #LightweightWheels #PerformanceParts #AutoTuning
#tuningblog - das Magazin für Auto-Tuning und Mobilität!
😇 Dein Abo hilft uns: https://tublo.eu/abonnieren
✅ Source: RAYS WHEELS
➡️ Mehr Infos: https://www.tuningblog.eu/tipps_tuev-dekra-u-co/rays-te37-produktion-764437/
Die TE37 von Rays sind echte Ikonen im Tuning- und Motorsportbereich – ultraleicht, superstabil und mit einem Herstellungsprozess, der seinesgleichen sucht. Du bekommst hier exklusive Einblicke in die aufwändige Schmiedetechnologie, das Design-Finishing und die kompromisslose Qualitätssicherung. Ideal für Performance-Fans, Technik-Nerds und alle, die wissen wollen, was ihre Felgen wirklich können.
#RaysEngineering #TE37 #ForgedWheels #JDM
#Schmiederad #LightweightWheels #PerformanceParts #AutoTuning
#tuningblog - das Magazin für Auto-Tuning und Mobilität!
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MotorTranskript
00:00Untertitelung des ZDF für funk, 2017
00:30Kombining materials and technology to create the ultimate in aluminum wheels.
00:34Let's see how these forged wheels are made.
00:45The manufacture of forged wheels begins with the selection of the best possible material.
00:52Based on the aluminum 6061 alloy, these billets are comprised of our original premium blend aluminum alloy,
00:59developed with an emphasis on strength.
01:04Prior to forging, the billets are first heated to over 500 degrees Celsius
01:09to enable the material to be shaped into various innovative designs.
01:13Using the heated billet material, we finally move on to the modeling forging process.
01:28TE-37 Saga wheels are shaped using mold form forging dyes in three stages.
01:39In the first forging, the billet material is made into a pancake shape
01:52with a diameter close to that of the finished wheel.
01:58The forging press applies several thousand tons of pressure,
02:01approximately five tons per square centimeter.
02:04From the second forging, a step-by-step mold forging from the pancake shape is performed.
02:14To achieve lightweight spokes, the cross-sectional shape is formed by forging from the back side.
02:35As you can see from the 3D model, the center of the spokes is hollowed out.
02:42Next is the third and final stage of shape forging.
02:57Together with the wheel design's overall shape, the hollowed out portions formed in the second forging
03:02are transformed into U-shaped cross-sections, characteristic of thin-walled forging.
03:07Lightweight is the aim of this final stage,
03:13and a seamless grain flow is achieved through this unique die-forging method
03:17to obtain the desired design, strength, and rigidity.
03:21This die-forging method employs Ray's Engineering's proprietary shuttle-type die-forging system.
03:36Ray's Engineering developed a shuttle-forging press machine
03:49that slides the forging die sets from three directions to perform the first, second, and third forgings.
04:01This forging press can apply a forging pressure of up to 10,000 tons.
04:05The key to maximizing forging performance is the forging die's design.
04:17In the three-stage forging used to transform the billet material into a wheel shape,
04:23the wheel's design side and reverse side are integrally shaped by three-dimensional shaping using the die-forging method
04:29to form high-strength, high-rigidity, U-shaped cross-sections for the spokes.
04:39Ray's Engineering's designers combine expertise, creativity, and a thorough understanding of the materials
04:45and manufacturing equipment with leading-edge forging technology.
04:49This RM forging machine is also our original technology.
04:59In addition to forming the final detailed shape,
05:03it uses proprietary dies to simultaneously form the outer rim and the flaring of the inner rim.
05:09Similar to the mold form forging process,
05:13the material is heated,
05:15and the heated wheel is rotated as the roller flares the inner rim.
05:24When metal is heated and compressed,
05:26such as in forging,
05:27fiber-like lines called grain flow appear.
05:35No machining is used to form raised wheels.
05:37Only the mold form forging made possible with our unique die-forging method,
05:42guided by the experience and knowledge of our design engineers.
05:46As a result,
05:47the grain flow lines fan out from the center of the wheel in a distinctive pattern,
05:51like the fibers of bamboo.
06:03This spinning process forms the inner rim's final shape.
06:06Inner rim molding from 5J to 13J is possible with a flexible mold,
06:12by taking advantage of the elongated characteristic of the aluminum alloy that is uniquely compounded.
06:19Following forging and rim forming,
06:33the aluminum alloy is heat-treated in order to maximize its unique properties.
06:37The heat treatment process consists of quenching and tempering.
06:46This heat treatment process is precision controlled to maximize the aluminum alloy's three key mechanical properties,
06:52of tensile strength, proof stress and elongation.
06:55As a result, even with a lightweight, thin-walled rim,
06:59good steering stability and suspension stiffness are maintained during cornering.
07:04The material of the forged wheel, which has undergone heat treatment,
07:06undergoes mounting processing,
07:23The material of the forged wheel, which has undergone heat treatment,
07:32undergoes mounting processing in advance of the tire inflation and vehicle attachment processes.
07:41In two processes, both the outside and inside of the wheel are machined
07:46to achieve a precise balance within 1 1,000th of a millimeter, an essential factor.
07:53PCD drilling is another process that requires high precision,
08:00since the balance of the wheel's mounting points on the vehicle is a critical factor.
08:11The air valve hole is also drilled parallel to the well angle of the wheel.
08:16Burrs, remaining from machining on the spoke edges, can reduce corrosion resistance after painting.
08:31To prevent this, Ray's Engineering developed a method using a special tool
08:35that rounds the spoke edges on the rear side of the wheel during the machining process.
08:39This edge trimming ensures better adhesion of the coating film
08:46that's formed in the painting process, improving corrosion resistance for the wheels,
08:51which are subjected to corrosive conditions due to their proximity to the road surface.
08:56This edge trimming method is a patented Ray's Engineering technology.
09:08Knurling is a process that improves wheel performance on race cars and other high horsepower vehicles.
09:14It helps prevent slipping between the tire and the wheel that might occur due to repeated, sudden acceleration and deceleration.
09:27Edi current testing is used to inspect for hairline cracks invisible to the naked eye.
09:41In particular, the camber force that is repeatedly exerted on the inner rim edges during driving
09:46can cause cracks to appear in the rim if there are any internal defects,
09:50leading to a loss of driving performance that could potentially pose a serious risk.
09:55Considering possible worst-case scenarios, each wheel is methodically inspected for defects.
10:05Wheel strength, rigidity, and balance are essential to ensure safe, comfortable driving.
10:13All three factors are numerically verified right from the design stage.
10:20Here as well, our designers' knowledge and experience are a solid foundation
10:24for design plans to create ideal wheels that are strong, lightweight, and beautiful.
10:31Proven designs are the basis for Ray's Engineering's wheel manufacturing.
10:43Radial load fatigue tests evaluate disc fatigue durability.
10:46The Japanese government's JWL standard requires 100,000 rotations, but Ray's Engineering has set its own plus R standard of 200,000 rotations.
11:01This ensures sufficient performance to withstand the lateral g-force during cornering in severe driving conditions.
11:06Simulations at the design stage enable predictive design to guarantee the required lower limit.
11:18Now let's look at the appearance-related processes.
11:22In the final stage of manufacture, the wheel surfaces are carefully polished by hand to remove the lubricant applied during mold form forging,
11:29as well as galling marks from hot forging, so as to ensure a beautiful finish for subsequent decorative painting.
11:41This work relies on the skill of Ray's Engineering's dedicated staff.
11:45Shot blasting has two purposes.
11:56First is to increase strength.
12:00While the forging, heat treatment, and machining processes already ensure ample strength,
12:04shot blasting is performed using stainless steel beads to make the wheels even stronger.
12:08Second is to level the forged surfaces.
12:12Painting the forged surfaces as is would not achieve the desired beautiful appearance.
12:25Wheel surfaces are degreased prior to the powder-coating undercoat.
12:30There are three processes, alkaline etching, acid pickling, and chemical conversion coating.
12:36A chemical conversion coating is formed on all wheel surfaces to ensure good adhesion of the paint and enhance corrosion resistance.
12:45The rotary degreasing system seen here uses a dipping method patented by Ray's Engineering that ensures a uniform chemical conversion coating.
12:55The powder-coating undercoat is then applied to the degreased wheel.
13:06The advantage of this powder coating is that its thickness enhances anti-corrosion performance.
13:15It also serves to level any unevenness of the forged surfaces.
13:19After the undercoating, a variety of solvent coatings can be applied depending on the desired specifications for each wheel.
13:29According to the design specifications, diamond cutting is performed after painting for a lustrous shine.
13:48Our original aluminum alloy material is characterized by its lustrous shine.
13:53Designs that bring out that luster are achieved using diamond chips.
13:58This is essential for deep rim specification wheels that have a deep outer rim.
14:03To maintain the anti-corrosion performance of the diamond cut surfaces, diamond cut wheels are treated using the rotary degreasing system seen earlier.
14:19This entails the same three processes, alkaline etching, acid pickling, and chemical conversion coating.
14:29Again, the Ray's Engineering patented dipping method ensures a uniform chemical conversion coating.
14:41A clear coat needs to be applied to the diamond cut wheels as soon as possible after degreasing.
14:46So, after air blow drying, the wheels are sent to the painting booth area.
14:50The wheels are transferred to the solid coating booth area.
14:53Ray's Engineering factory automation line system prioritizes anti-corrosion performance.
15:03After degreasing, the wheels are transferred by robot or PLC controlled lines to the solvent coating booth area.
15:18The clear coat is applied in two stages.
15:31First primer, then the clear coat.
15:33A variety of transparent and colored clear coats are available to meet specific needs.
15:37The e.g.
15:41A area of deprive with specific needs.
15:42A variety of pull needs to be applied with specific needs.
15:44A涼
15:56A variety of fresh features and Prague's friendly with specific needs.
16:01The most prominent feature of AMT, Ray's advanced machining technology,
16:12is the ability to engrave markings on wheels after a coating has been applied.
16:22With AMT, the grooves cut by the machining tool are left as is.
16:28This enables letters and other delicate markings to be engraved as continuous lines.
16:34No matter how difficult the engraving, our proprietary machining center achieves a production speed and quality rivaling mass-produced products.
16:46With RE-DOT, Ray's engineering drawing object technology, a bubble jet spray system is used to apply a second coating of solvent onto the wheel design face as an accent color after the first color has been applied.
17:09Employing application devices with coating supply heads that make possible the application of colors and decorative designs,
17:21Ray's AMT and RE-DOT are leading edge technologies that achieve mechanical designs never before possible to reach new heights in wheel design.
17:31As you've seen, most forged wheel manufacturing processes are performed by machines.
17:39But the final inspection requires human eyes and hands.
17:43Inspectors apply all of their considerable knowledge and expertise.
17:48As the final inspection is the closest step to the end user, it can only be performed by expert craftsmen with years of experience.
17:57Before finished wheels are released onto the market, they undergo a battery of durability tests.
18:04Here, the rim disc's strength and its ability to hold the tire's air after a hard impact are assessed.
18:12In the JWL standard impact test, a weight of 500 to 600 kilograms is dropped from a height of 230 millimeters to assess impact resistance.
18:28But that's not enough for Ray's engineering.
18:31The plus R standard from a height of 305 millimeters is used to assess the impact force exerted on the wheel, such as when driving over a curb stone or a speed bump.
18:44Die forging gives Ray's wheels the resilience to withstand such impacts and is verified in simulations from the design stage.
18:52Wheel durability is assessed using drum endurance tests.
18:58The JWL standard requires 500,000 rotations, but Ray's engineering has set its own plus R standard of 1 million rotations to ensure that wheels can withstand vertical loads exerted by continuous driving in severe conditions.
19:13Ray's wheels can meet this high standard because the forged material has a high fatigue strength and the wheel's composition is uniform, so the strength is also uniform.
19:34The certification stickers are applied to wheels that satisfy the plus R standard.
19:43These stickers are proof of having passed the most rigorous testing.
19:56Ray's engineering's original forged wheels.
20:01Thanks to unique wheel designs that meet global demand and the advanced proprietary technologies used to manufacture them,
20:08Ray's engineering continues to be a leader in the field.
20:16Taking forged wheels to impressive new heights.
20:20Ray's engineering.
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