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Most alloy wheels are manufactured using casting, but some are forged. Forged wheels are usually lighter, stronger, but much more expensive than cast wheels. There are two types of forged wheels: one piece and modular. Modular forged wheels may feature two- or three-piece design.
The main disadvantage of forged wheels is the high manufacturing cost. Owing to the typically high costs of finished wheels, forged wheels are still rarely purchased by non-professional drivers for regular road use. But since forged wheels can be designed to be lighter than cast wheels for a given load, forged wheels do offer fuel economy and ...
A 1977 Harley-Davidson XLCR with seven-spoke alloy wheels manufactured by Morris [8]. High-performance motorcycles began to use cast alloy wheels (usually aluminum but sometimes magnesium) as early as the Münch Mammoth, with its single cast-elektron [9] rear wheel which was shown at the Intermot motorcycle show at Cologne in late 1966. [10]
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True-forged wheels are up to 30% lighter than regular/standard OEM cast wheels. An additional 20% in weight can be saved by upgrading to forged magnesium wheels, such as those employed by F1 and MotoGP teams. [11] Three companies are known to produce true-forged magnesium wheels: BBS Japan [12] Tan-ei-sya (TWS) [13] SMW Wheels [14]
BBS continues to produce one-, two-, and three-piece forged wheels out of aluminum and magnesium alloys, as well as high performance flow-formed wheels and low-pressure cast wheels. [20] BBS also actively uses specialized quality and weight optimization methods, such as CNC back-milled spokes , x-ray inspection , FEM analysis, flow-forming ...
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