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The Forging Process – Steps on the way to perfection

Forging – a complex process, which must provide the maximum in safety.

In a series of steps, the wheel is prepared for its important task for a long automotive life.
The process control guarantees excellent material properties, which are the reasons for the low weight of our forged wheels. Forged wheels also offer the occupants the optimum level of safety in critical driving situations.

Step 1: The cast bar
A cast block also produced by OTTO FUCHS of over 6 m in length, is the starting material from which a blank is sawn off, exactly matching the later wheel.
Step 2: The preliminary forging
In the first forging stage, the blank is forged into a rotationally symmetric piece under a force of 4,000 tons.
Step 3: The design forging
In the second forming stage, the styling is pressed into the pre-forged blank in a 7,000 tonne press, which largely gives the wheel its later appearance.
Step 4: The perforation
In the last forging stage with 800 tonnes of press force, the ventilation holes and the hub are stamped out, and the burring of excess material around the circumference cut off.
Step 5: The flow-forming
The outer edge of the wheel is heated. The complete rim area, from the outer to the inner flange, is rolled out – which is exactly what goes to make a Fuchsfelge®.
Step 6: The finishing
The finishing takes place in the last step: turning, drilling and deburring. The complex process is rounded off by painting.