Manufacturing Wheels
Design, Engineering, Finite Element Analysis (FEA) & Programming
Design is the most important aspect of Forza Performance Group forged wheels. Combining lightweight and high strength, we produce wheels with outstanding designs. But with wheels, you can't sacrifice everything for design. First, the wheel and tire must clear the fender arch of the vehicle on which it is installed, and the wheel must also provide sufficient clearance for the brake calipers.
Each car make and model has different dimensions and clearances, as well as different overall aesthetics. Using our extensive measurement process, Forza Performance Group's forged wheels are optimized specifically for each vehicle, maximizing concavity and improving the overall fit.
Forza Performance Group's wheels go through a rigorous design and development process. that ensures a precise end product covering all the dynamic needs of our customers' vehicles while ensuring their tastes from finish and configuration to packaging. Every Forza forged wheel design is physically tested to SAE, JWL, VIA, and TUV standards. Using finite element analysis (FEA) software. Each wheel is tested for vehicle-specific steering, radial, and shock loads.
After the design, a CAD model of each wheel is programmed for processing using a computer program (CAM). The program, or G-Code, is designed using CAM to guide the paths of each machine while ensuring that the final wheel exactly matches the intended CAD model.
Wheel forgings and machining process
Quality materials are the basis for a quality result. The forgings we use for
Forza Performance Group's forged wheels are manufactured in a high-tech fully automated IATF16949 and ISO9001 factory with an ultrasonic material detector line and three presses providing a maximum pressure of 12,000 tons.
After pressing, the forgings are subjected to T6 heat treatment to create a high-strength multidirectional grain structure. The aluminum remains solid throughout the entire process as the die pushes the aluminum towards the cylindrical shape of the wheel. The result is higher strength.
6061-T6 aluminum forgings ensure high quality forged wheel. This provides a superior foundation that guarantees durability and a reliable, high-performance product that meets our team's highest standards.
CNC Machining
At this stage of production, the forged blank is gradually transformed into a forged wheel with a developed design. Forza Performance Group's wheels have 11 CNC machines for the production of forged wheels. Lathes are used to achieve high concentricity of the cylindrical workpiece, milling machines with high rigidity and spindle speed provide a smoother surface.
The use of high-quality CNC machines enables us to achieve the highest tolerances while minimizing defects on the surface of the forgings.
Once the face design is complete, the wheel is rotated 180 degrees for additional milling. Lightening pockets are milled into the rear wheel pad and the rear wheel pockets to minimize weight where possible.
Post-milling and hand preparation
Each piece of shredded aluminum billet goes through many stages of deburring, hand-feeding, polishing, and polishing before it is ready for coating. The toolboxes processes enable our craftsmen to hem and sculpt each profile flawlessly, each edge receiving the attention of several hands before it is prepared for final coating.
Finishing process
Our team uses a combination of liquid paint and powder coating processes. Finishing is the final process that determines the appearance of the wheel. Forza Performance Group's forged wheels go through a coating process in several stages: powder coating + baking + paint coating + baking + powder coating + baking. A total of three layers of coating processes. Attention to detail is what sets Forza Performance Group wheels apart.
We always strive for perfect color choices and only select the highest quality powder coatings and paints to offer our customers a superior product.
Precision requires consistency and consistency requires control, which is why the Forza team carefully checks each wheel at every step of the process. Forza specialists check each wheel for accuracy before moving on to the next step.
The QC team validates every critical measurement according to a detailed engineering diagram. The beating, the measurement of the roundness of the spinning wheel, is most important. Forza forged wheels have been tested for runout tolerance.
Quality control
Accuracy requires consistency, and consistency requires control, which is why the Forza team carefully checks each disc at every stage of the manufacturing process.
The QC team validates every critical measurement according to a detailed engineering diagram. The measurement of the roundness of the spinning wheel is most important. Forza forged wheels are tested for runout tolerance.