Sustainability Assessment of the UMPs involved in

Automobile Wheel Manufacturing

Esther Ojokojo
Project Goal
The production of automobiles is at the core of the automotive industry. Transportation of both man
and goods or services is of very vital importance to accessibility of necessities, trade; an essential for the
development of civilizations and many other aspects of the human society. The number of automobiles
built increases yearly, from 72.1 million passenger cars in 2016 to 73.5 million in 2017 with an expected
rise to 81.6 million in 2018 [1]. At the heart of automobile production is the tire and wheel system. This
is the system that connects the automobile to the road ensuring movement. The need to therefore
engage in sustainability analyses of the manufacturing processes involved in the production line of this
system is very vital in ensuring that we “meet present needs without compromising the ability of future
generations to meet their needs” [2]. The goal of this project therefore is to carry out a sustainability
analysis of some of the Unit Manufacturing Processes (UMPs) involved in this production line; providing
an insight into improvements that can be made in the generalized automobile manufacturing to make it
more sustainable.

Object/Activity
The tire and wheel system is comprised of a very large number of manufacturing or production lines that
all play a role in the creation of the various parts that make up this system. Of particular interest in this
analysis are the processes involved in the Wheel manufacturing.

Performance Area
This evaluation is focused on effects of the manufacturing processes of the wheels of the vehicle on the
environment. Ways in which the processes can be modified or changed to reduce adverse effects on the
environment will have advantages which will be enjoyed by both the manufacturers and the
environment. Cost benefits, reduction in pollution are a few of these benefits.

Indicators
Wheel manufacturing can be analyzed by various indicators outlined in Table 1 below. It is important to
note that this table does not provide a complete list of indicators. As stated earlier, this study focuses on
the indicators that challenges and have numerous negative impacts on the environment.
Table 1 Sustainability Indicators and their descriptions

Indicator Description
Energy The amount of energy consumed by the UMPs to produce the steel wheels.
Waste Waste material, thermal energy discharge, lubricants, noise and air pollutants
Water The water used majorly in the cooling operations carried out
Processes
Depending on the type of wheel to be produced and the material to be used, the production processes
differ. This study analyzes the production process of Steel Wheels. The Wheel manufacturing production
line is comprised of 2 UMPs. The formation of the wheel disk and the formation of the wheel rim. [3], [4]
After being individually manufactured, the wheel rim and disk are assembled together to form the
wheel. Table 2 gives a description of the steps in the disk production. Table 3 outlines the formation of
the wheel rims with each step/sub operation description.
Table 2 Description of Production Steps for the Wheel disk

Step Description
Blanking The metal sheets are blanked to form the circular workpiece from which the
disks will be formed.
Drawing The metal blanks produced in the previous stage are drawn to form the dome
shape of the disk. This process is typically carried out 3 times. The first
drawing, the second drawing and the reverse drawing. The stages are done to
ensure that the desired shape is achieved.
Trimming The spoke flanges are trimmed, and the central hub and bolt holes are pierced
in the disk.
Flanging The central hub is flanged and the disc is once more drawn to its final shape.
Bolt Hole Coining The bolt holes are coined.
Vent hole piercing Vent holes are pierced in the outer periphery of the disk. These holes are then
and Coining coined.
Table 3 Wheel Rim production steps and a brief description

Step Description
Cutting A strip of steel is cut to the length specified by the customer to form the rim
band.
Feeding A single piece of rim band is fed or loaded unto the coiler machine.
Deburring The burrs at both edges of the rim band are removed to protect molds and
operators from scratches during subsequent processing stages.
Stamping The stamper presses the needed marks into the band. Marks convey the
manufacturing information.
Coiling The rim band is coiled to form the wheel rim.
Flattening The ends of the coiled wheel rim are flattened to make the welding process
easier.
AC Flash Butt The ends of the rim are welded together by a resistance welding technique
welding involving no material addition in a two-step process; flashing and upsetting.
Trimming This is done to remove the weld slag on internal and external surfaces of the weld
joint in a bid to flatten it.
Planishing The joint is planished to flatten and reinforce the weld joint after the slag has
been removed.
End-Cutting The leftover material at both ends of the weld joint is cut off.
Cooling The wheel rim is cooled.
Re-rounding The flattened end of the wheel rim is re-rounded.
Flaring The two edges of the rim are flared into a horn mouth to make the roll forming
process easier.
 Forming Symmetric or asymmetric roll forming is done on the wheel rims. This is done in 4
steps.
Flanging The rim wheel edges are flanged.
Expanding Expanding and sizing of the wheel are done to ensure that the wheel conforms to
the desired requirements.
Punching Valve holes are punched into the rims creating the stem through which air is
pumped into the tires after they are affixed.
Pressing The wheel disk is pressed into the rim to form the steel wheel.
Welding/Bolting Depending on the application of the wheel, either in passenger cars and trucks or
in farm or large vehicles, the disk may be either welded or bolted respectively to
the rim.

Metrics
Table 4 below provides the sustainability metrics that will be associated with a complete evaluation of
the manufacturing process of wheel manufacturing [5].

Metric Description
Energy The total energy required in the production of a wheel. Which will include
Used(kWh/wheel) the energy required in producing the disk, the rim and assembling them
together.
GHG Emission The total amount of gases produced if any during the manufacturing of
one wheel.
Total Waste The total amount of waste produced form the manufacture of one wheel.
Water The total amount of water used if any during the production process of
Usage(liters/Wheel) one wheel.
Table 4 Sustainability Metrics

Boundary Conditions
The scope or boundary of this evaluation is limited to the metal working done in the wheel
manufacturing line of the automobile production. The Finishing, and testing stages are not included in
this analysis. i.e. the painting and drying of the wheel post-production, the packaging and storage.
Additionally, we assume that the lines are fully automated and that loading and transfer of parts
between each of the stages is mechanized.

Input and Output Parameters

The input and output parameters for the two unit processes are given below with a brief description for
each. Table 5 describes the input output parameters for the Wheel disk production process and table 6
describes same for the Wheel rim production process.
Table 5 Input Output Parameters for the Wheel disk Production Process

Input Description
Steel sheets The main raw material worked on to produce the steel disk.
Energy The operation of the machines requires energy in the form of electricity
to run.
 Output Description
Steel disk The key output of the production process.
Waste Left over metal from the machining processes,
Table 6 Input and Output Parameters of the Wheel Rim Manufacturing Process

Input Description
Low Carbon Steel Strip The rim of the wheel is produced from a single strip of carbon steel that is
bent, coiled and welded into shape.
Energy The machining operations all require electricity to run.
Gas The welding operation requires shielding gas (argon gas), flammable gas
(natural gas).
Water The cooling step of the machining process requires water.
Output Description
Wheel Rim The desired output of the production process.
Waste The materials removed from the machining processes, weld slag, machine
emissions, noise, lubricant wastes, water waste, exhaust from the
cooling.

Process Model
A process model for Wheel manufacturing is given in figure 1 below. The sub operations of the disk
manufacture is further broken down into input and outputs in figures 2 and Table 3 identifies the inputs
and outputs of some of the rim manufacturing sub operations.

Figure 1 Wheel Manufacturing Process (showing the rim production line and final assembly of rim and disk)
 Inputs Outputs
Metal Strip -Circular Blanks
Hydraulic Fluid BLANKING -Scrap Metal
Electricity -Lubricant and
Lubricant Hydraulic Fluid
Waste

Inputs Outputs
Circular Blanks -Drawn Dome-
Hydraulic Fluid Shaped Metal
DRAWING
Electricity -Lubricant and
Lubricant Hydraulic Fluid
Waste

Inputs Outputs
Dome Shaped -Trimmed Disk with central hub
Metal and bolt holes
TRIMMING
Hydraulic Fluid -Lubricant and Hydraulic Fluid
Electricity Waste
Lubricant -Emissions

Inputs Outputs
Trimmed Disk -Flanged Drawn Disk
Hydraulic Fluid FLANGING -Lubricant and
Electricity Hydraulic Fluid
Lubricant Waste
-Emissions

Inputs Outputs
Flanged Drawn -Coined Disk
Disk -Lubricant and
COINING
Hydraulic Fluid Hydraulic Fluid
Electricity Waste
Lubricant -Emissions

Inputs Outputs
Coined Disk -Final Wheel Disk
Hydraulic Fluid PIERCING AND -Lubricant and
Electricity COINING Hydraulic Fluid
Lubricant Waste
-Emissions

Figure 2 Input-Output Diagram of the Disk Manufacturing Process

Table 7 Input-Output Parameters of some specific Rim Manufacturing Sub-operations

Sub Step Operation Inputs Outputs

AC Flash Butt Welding Coiled rim band with flattened
edges, shielding gas (argon gas),
flammable gas (natural gas),
High pressure, High current and
Voltage Electricity.
Cooling Welded trimmed rim part,
Water, electricity
Punching Expanded rim, Hydraulic Fluid,
Electricity, Lubricant
Welded wheel rim, waste gases,
Emissions
Cooled rim, exhaust, waste
water, Emissions
Wheel rim with valve holes,
scrap material, lubricant waste,
hydraulic fluid waste heat,
emissions

The data for the involved equipment is also provided in a bid to analyze the energy consumption for
each of the steps in the rim manufacture of a small wheel [3].
Table 8 Rim manufacture UMP Equipment Set

Equipment Processes Specifications

Coiler Machine
AC Flash Butt Welding
Machine (UNB2-630)
Trimmer(BZJ),
Planisher(GYJ), End
Cutting(DQJ) Machine
Horizontal Flaring
Machine(KKJ-315)
Roll Forming
Machine(GX-23/300)
Horizontal Expanding
Machine (KZJ-200X2)
Valve Hole Punching
Press(YPCK-400)
Feeding, Deburring, Stamping Input Power=11.5kW; Power Supply = AC
and Coiling 380V/3phase/50Hz
Clamping, Flashing, Burn-off, Input Power = 630kVA; Power Supply = AC
Upsetting 380V/3phase/50Hz; 6.55V to 11.8V
Max. upsetting force 280KN Max. clamping
force 650KN
Trimming, Planishing and Input Power = 37kVA; Power Supply = AC
End-Cutting 380V/3phase/50Hz; Hydraulic System
Pressure= 12Mpa
Flaring Rated Operation Pressure 16MPa;
1st ,2nd and 3rd forming Rolling force = 230KN; Motor Power=
processes 62.5Kw Input Voltage= 380V
Expanding Expanding force = 1600KN; Rated hydraulic
pressure = 20MPa; Installed power = 22KW
Valve hole punching Punch force = 250kN; Motor Power=
11.5kW

Required Resources
For this sustainability analysis to be successfully carried out, there is the need for data collection and
evaluation. The collected data would be used in computing the metrics selected for the analysis.
Measurement equipment can be used in collecting this data.

For the metrics indicated above, there would first be a need to measure the total amount of energy
consumed by each UMP. As the machines required for each of the sub operations uses electricity, the
amount of energy consumed by each in the production of one wheel needs to be collected. Additionally,
the thermal energy generated from the usage of these machines must be accounted for.

The amount of sheet metal used in the production of both the wheel disc and the wheel rim is of utmost
importance. The rate of consumption of said sheets should also be put into consideration to provide
knowledge of how many wheels can be produced in a given time frame. This can enable production
analysis. The number of manufacturing defects will also be needed to get proper and more accurate “for
one wheel” data.

With regard to waste generation, a lot of information is required. There is a lot of scrap metal produced
in the run of this production line. The amount or percentage of the sheet metal not consumed in the
process but released as scrap is a required resource. As majority of the processes in the wheel
production is machining, the amount of lubricant used and discarded is also a required resource. The
recyclability of this lubricant materials need also be looked into for sustainability in the entire process.
There is also the large amount of noise these processes produce and this also in some way needs to be
taken account of. In the flash butt welding process, there is the need for the addition of some gases. The
amount of shielding and flammable gases needed, and the waste generated is required. The amount of
pressure and additional current requirements also need to be measured and data collected.

References

[1] I. O. o. M. V. Manufacturers, "OICA President Wissmann: World Automobile Market Continues to

Grow," in Proceedings of Geneva International Motor Show, 2017.

[2] WCED, "Report of the World Commission on Environment and Development: Our Common Future,"
UN Publisher, 1987.

[3] Shandong Xiaoya (LittleDuck) Precise Machinery Co., Ltd, "STEEL WHEEL RIM MANUFACTURING
LINE," LittleDuck Group.

[4] Yoochang Powertech, "Steel Wheel Disc".

[5] M. Mani, J. Madan, J. H. Lee and K. W. Lyons, "NIST Interagency/Internal Report (NISTIR) - 7913:
Review on Sustainability Characterization for Manufacturing Processes," NIST Pubs, 2013.