US3735719A

US3735719A - Wheel lug

Info

Publication number: US3735719A
Application number: US00142947A
Authority: US
Inventors: O Puzik
Original assignee: WILLOW HILL IND Inc
Current assignee: WILLOW HILL IND Inc
Priority date: 1971-05-13
Filing date: 1971-05-13
Publication date: 1973-05-29
Anticipated expiration: 1990-05-29
Also published as: CA979949A

Abstract

A method of making an improved wheel lug for use in securing a removable or demountable tire carrying rim to the hub of a wheel assembly includes the cold working of a circular flat metal blank to form a cup-shaped blank which is then cold worked to the configuration of the wheel lug. The flat metal blank or disc is first formed into a cup-shaped blank having a generally hemispherical configuration. A side portion of this hemispherical cup-shaped blank is cold worked to form four rectangular side panels. These side panels are integrally formed with each other to define an uninterrupted and joint free rectangular rim and side wall of the cup-shaped blank. The arcuate bottom of the cupshaped blank is then cold worked to form a generally flat rectangular main or bottom panel. Finally, the rectangular side and bottom panels of the cup-shaped blank are cold worked to the configuration of the wheel lug. During this final cold working of the cup-shaped blank, one side panel is bowed outwardly at the same radius of curvature as a clamp surface on the rim of the wheel assembly. In addition, the opposite side panel is bowed inwardly at the same radius of curvature as a clamp surface on the hub of the wheel assembly. The side panels of the finished wheel lug are integrally formed with each other without an interruption or joint between them to provide the wheel lug with sufficient strength to withstand relatively severe operating conditions.

Description

ijnited States Patent [191 Puzik 1 WHEEL LUG [75] Inventor: Otto V. Puzik, Willoughby, Ohio [73] Assignee: Willow Hill Industries, Inc., Willoughby, Ohio [22] Filed: May 13, 1971 [21] Appl. N0.: 142,947

[5 6] References Cited UNITED STATES PATENTS 1,156,972 10/1915 Carlson ..72/349 830,193 9/1906 Andersson.... .....72/348 1,122,753 12/1914 l-lolinger ..72/349 1,948,437 2/1934 Bowers ..72/348 3,456,479 7/1969 Matveev et al. 10/86 R Primary ExaminerRichard J. Herbst Attorney-Yount and Tarolli [57] ABSTRACT A method of making an improved wheel lug for use in [451 May 29, 1973 securing a removable or demountable tire carrying rim to the hub of a wheel assembly includes the cold working of a circular flat metal blank to form a cupshaped blank which is then cold worked to the configuration of the wheel lug. The flat metal blank or disc is first formed into a cup-shaped blank having a generally hemispherical configuration. A side portion of this hemispherical cup-shaped blank is cold worked to form four rectangular side panels. These side panels are integrally formed with each other to define an uninterrupted and joint free rectangular rim and side wall of the cup-shaped blank. The arcuate bottom of the cup-shaped blank is then cold worked to form a generally flat rectangular main or bottom panel. Finally, the rectangular side and bottom panels of the cup-shaped blank are cold worked to the configuration of the wheel lug. During this final cold working of the cup-shaped blank, one side panel is bowed outwardly at the same radius of curvature as a clamp surface on the rim of the wheel assembly. In addition, the opposite side panel is-bowed inwardly at the same radius of curvature as a clamp surface on the hub of the wheel assembly. The side panels of the finished wheel lug are integrally formed with each other without an interruption or joint between them to provide the wheel lug with sufficient strength to withstand relatively severe operating conditions.

15 Claims, 15 Drawing Figures PATENIEUHAYQQW 37,35,719

SHEET 1 OF 3 //VVEN7'0R 0770 M PUZ/K PATENTEMHY29I975 313571 9 SHEET 3 OF 3 ATTORNEYS 1 WHEEL LUG This invention relates to a new and improved wheel lug for use in securing a removable tire carrying rim to the hub of a wheel assembly and a new and improved method of making awheel lug.

Certain types of wheels for trailers and other vehicles include a demountable or removable tire carrying rim which is connected with the hub of the wheel by a clamp or fastener assembly. This fastener assembly includes a wheel lug which clamps the rim against the hub of the wheel. Wheel lugs have previously been made by casting, forging, and stamping processes. Known wheel lugs made by casting or forging processes have sufficient structural strength to enable them to be used in wheel assemblies on trailers and other vehicles. However, these wheel lugs are relatively expensive to fabricate. Although stamped wheel lugs are inexpensive to fabricate, known stamped wheel lugs are relatively weak and are unsatisfactory under severe operating conditions.

The present invention provides an improved stamped metal wheel lug which is capable of withstanding relatively severe operating conditions. This wheel lug has a rectangular face or bottom panel which is circumscribed by a strong continuous side wall formed of panels which are integrally interconnected. One of thepanels of the side wall is conveny curved to engage the rim of a wheel assembly while the opposite panel is concavely curved to engage the hub of the wheel assembly. In accordance with the present invention, this wheel lug is made-at a relatively low cost by a method which includes cold working a flat metal blank toform a cup"- shaped blank having-an uninterrupted rim which is free of joints. This cup-shaped blank is then cold worked to th'e' co'nfiguration of the wheel lug.

Accordingly, it is the object of this invention to provide a new and improved method of making a wheel lug for use in securinga removable tire carrying rim to the hub of a wheel assembly, wherein the method includes the steps of providing-aflatmetal blank and cold working this blank to form a cup-shaped blank which is then cold worked to the configuration of the wheel lug.

Another object of this invention is to provide a new and improved method of making a metal wheel lug for use in securinga removable tire carrying rim to the hub of a wheel assembly wherein this method includes the steps of providing 'a flat metal blank having a continuously curving'outer edge, cold working the flat blank to form a cup-shapedblankwith'an uninterrupted rim and a side portion having a continuously curving cross sectional configuration in a plane between the rim and a bottom portion of the blank, cold working the bottom portion of the cup-shaped blank to a generally flat rectangular configuration, cold working the side portion of the cup-shaped blank to form generally rectangular sides extending transversely to the bottom portion of the cup-shaped blank, and cold working a pair of these sides to shape them forengage'ment with the rim and hub of the wheel assembly.

Another object "of this invention is to provide a new and improved meth'od of making a wheel lug for use in securing a removable tire carrying rim to the hub of a wheel assembly wherein the method includes the steps of providing a Hat circulardisc, cold working this disc to form a cup-shaped blank having a generally hemispherical configuration, and cold workingbottom and side portions of the cup-shaped blank to form a rectangular bottom and four intersecting sides extending transversely to the bottom.

Another object of this invention is to provide a new and-improved wheel assembly which includes a removable tire carrying rim, a hub for supporting the rim and a retainer assembly for retaining the rim against movement relative to the hub, and wherein the retainer assembly includes a stamped metal wheel lug having a convexly curved side portion disposed in abutting engagement with a concavely curved surface on the rim of the wheel assembly and another side portion having a concavely curved outer surface which is disposed in abutting engagement with a convexly curved surface on the hub of the wheel assembly.

These and other objects and features of the invention will become more apparent upon a consideration of the following description taken in connection with the accompanying drawings wherein:

FIG. 1 is a fragmentary sectional view of a wheel assembly which includes a removable tire carrying rim held onto a hub by a wheel lug constructed in accordance with the present invention;

FIG. 2 is an enlarged plan view, taken generally along the line 2-'-2 of FIG. I, further illustrating the wheel lug;

FIG. 3 is a sectional view, taken generally along the line 3-3 of FIG. 2, illustrating the relationship between the wheel lug and the rim and hub of the wheel assembly of FIG. 1;

FIG. 4 is a plan view taken generally along the line 4-4 of FIG. 3, illustrating'the bowed or curved configuration of clamp panels on the wheel lug;

FIG. 5 is a plan view of a flat circular steel disc or blank which, in accordance with the present invention, is cold worked to form the wheel lug of FIGS. 14;

FIG. 6 is a schematic illustration of a first work station at which the'fiat circular disc of FIG. 5 is cold worked to form a generally hemispherical cup-shaped blank;

FIG. 7 is an illustration of the hemispherical cupshaped blank formed at the work station of FIG. 6;

FIG. 8 is a schematic illustration of a second work station at which a side portion of the hemispherical cup=shaped blank of FIG. 7 is formed into four side panels interconnected by a continuous rectangular rim;

FIG. 9 isan illustration of the cup-shaped blank after completion of work operations at the work station of FIG. 8;

FIG. 1'0 is a sectional view, taken generally along line 10--l0 of FIG. 9, illustrating the circular cross sec tional configuration of a bottom portion of the cupshaped blank;

FIG. 11 is a schematic illustration of a third work station where the arcuate bottom portion of the cupshaped blank of FIG. 9 is cold worked to form a rectangular bottom or'main panel;

FIG. 12 is an illustration of the cup-shaped blank after completion of work operationsat the work station of FIG. 11;

FIG. 13 is asc'hematic illustration of a fourth work station at which rectangular side and bottom panels of the cup-shaped blank are further formed and at which indicia is stamped on the cup-shaped blank;

FIG. l4is a schematic illustration of a fifth work station at which the bottom panel of the cup-shaped blank is pierced; and

FIG. is a schematic illustration of a sixth and final work station at which side or clamp panels on the cupshaped blank are formed to the configuration of FIGS. 2-4.

A known wheel assembly having a removable or demountable rim 22 upon which a tire 24 is mounted is shown in FIG. 1. The rim 22 is clamped against a hub 26 by a fastener assembly 28. The fastener assembly 28 includes a bolt 32 and nut 34 which engages a wheel lug 36 constructed in accordance with the present invention. The wheel lug 36 presses inwardly against an annular inclined ramp or clamp surface 40 on the rim 22 and against an oppositely inclined ramp or clamp surface 42 on the hub 26 to clamp an annular surface 44 on the rim 22 against an outwardly projecting support section 46 of the hub 26. The hub 26 and a brake assembly 50 are mounted on an axle shaft or spindle 52 in a known manner.

The wheel lug 36 (see FIGS. 2 and 3) includes a rectangular main or bottom panel 60 which is pressed inwardly by the nut 34 of the fastener assembly 28 (FIG. 3). The pressure applied against the main panel 60 of the wheel lug 36 by the nut 34 presses a rectangular rim clamp panel 64 on the wheel lug into tight abutting engagement with the inclined clamp surface 40 on the rim 22. The pressure applied against the main panel 60 by the nut 64 also presses a rectangular hub or wheel clamp panel 66 into tight abutting engagement with the inclined clamp surface 42 (FIG. 3) formed on the hub 26. A pair of parallel side panels 72 and 74 (FIG. 4) extend between and support the rim and

hub clamp panels

64 and 66 to prevent them from being forced or collapsed inwardly under the influence of this pressure.

The rim clamp panel 64 and hub clamp panel 66 are arcuately curved to provide for continuous abutting contact between the entire surface areas of the rim and hub clamp panels and the

curved surfaces

40 and 42 on the rim 22 and hub 26 (see FIGS. 3 and 4). Since the rim clamp panel 64 engages the annular clamp surface 40 on the inside of the rim 22, the rim clamp panel is convexly curved, that is the rim clamp panel is bowed or curved outwardly with a radius of curvature 78 which matches the curvature of the rim clamp surface 40. Similarly, the hub or wheel clamp panel 66 is concavely curved, that is the panel is bowed inwardly with a radius of curvature 80 which matches the curvature of the hub clamp surface 42. Since the rim and

hub clamp surfaces

40 and 42 are concentric about the central axis 82 (FIG. I) of the wheel assembly 20, the

radii

78 and 80 emanate from the common axis 82.

The rim and

wheel clamp panels

64 and 66 are of generally uniform thickness and are inclined at the same acute angle relative to the main panel 60 (see FIG. 3) to position the rim and

wheel panels

64 and 66 in abutting engagement with the inclined

clamp sur faces

40 and 42 on the rim 22 and hub 26. The inclined rim and

hub panels

64 and 66 are supported against buckling inwardly by the parallel side panels 72 and 74 (FIG. 4) which are of uniform thickness and extend perpendicularly to the main panel 60. To strengthen the wheel lug 36, the side panels 72 and 74 and the rim and

hub panels

64 and 66 are integrally formed in a continuous wall which is uninterrupted and joint free between the various panels. Thus, the rim panel 64 is integrally formed with the side panels 72 and 74 and the main panel 60 without a joint at the corners between these panels. Similarly, the wheel or hub panel 66 is integrally formed with the side panels 72 and 74 and main panel without a joint at the corners between these panels.

In accordance with the present invention, the wheel lug 36 is made from a flat circular steel disc 88 (FIG. 5). In one specific embodiment of the invention, the flat steel disc had a diameter of approximately 2.1 inches and a uniform thickness of 0.1 19 inches and was formed of S.A.E. 1010 steel. Of course, the particular dimensions and shape of the flat disc 88 will vary depending upon the dimensions and shape of the wheel lug 36 to be formed from the disc. In addition, it should be understood that for certain applications the disc could be made of material other than S.A.E. 1010 steel.

The wheel lug 36 is formed from the disc 88 by first cold working the disc to form a hemispherical cupshaped blank 92 (FIGS. 6 and 7). An annular side portion 96 of the cup-shaped blank 92 is then cold worked to form a plurality of generally

rectangular side panels

102, 104, 106, and 108 (FIGS. 8 and 9) which are interconnected by an uninterrupted and joint-free rectangular rim 110. An arcuate bottom section or portion 114 having a circular cross-sectional configuration (FIG. 10) interconnects the

side panels

102, 104, 106, and 108.

The cup-shaped blank 92 is then cold worked to a generally cubical configuration (see FIGS. 11 and 12) by forming the arcuate bottom portion 114 into a rectangular bottom or main panel 118 (FIG. 11) which has a uniform thickness and will form the main panel 60 of a wheel lug 36. As the rectangular bottom panel 118 is formed, metal is plastically cold worked from the bottom portion to extend the rectangular side panel 108 of the cup-shaped blank 92 relative to the

other side panels

102, 104 and 106 (see FIG. 11). Indicia indicating which of the side panels is to engage the rim clamp surface 40 and the hub or wheel clamp surface 42 is then stamped on the blank 92 (FIG. 13) and the blank is pierced (FIG. 14) to provide an opening 122 (FIG. 2) for receiving the bolt 32. Finally, the

rectangular side panels

104 and 108 of the cup-shaped blank 92 are formed to the final configuration of the rim and wheel clamp panels 64 and 66 (see FIG. 15) to complete the formation of the wheel lug 36.

The disc 88 is advantageously made into the wheel lug 36 by utilizing a known dial type of punch press having a plurality of work stations. At each of these stations, the blank 92 is plastically deformed at a temperature below the crystallization temperature of the blank, that is the blank is cold worked. Once the cold working operation has been performed at one of these stations, a dial or carrier 128 transports the blank 92 to a next succeeding station where the next step in forming the disc 88 into the wheel lug 36 takes place. Although it is believed to be advantageous to utilize a known type of punch press wherein the various work stations are arranged in a circle and in which the dial 128 is indexed about the center of the circle to move the blank 92, the work stations could be disposed in any other desired relationship.

The circular disc 88 is positioned in a circular transfer chamber or cavity 132 (FIG. 6) in the dial 128 at a loading station (not shown). The dial 128 is then indexed to move the disc from the loading station to a first work station 134. A punch 138 is moved downwardly at the work station 134 to cold work the disc 88 from theflat configuration shown in dashed lines in FIG. 6 and in solid lines in FIG. 5 to the generally hemiface 144 which forms the blank 92 to a hemispherical configuration. It should be noted that the blank 92 has a continuous annular rim 150 which is uninterrupted by a seam or other joint. Although it is advantageous to form the cup-Shaped blank 92 to a hemispherical configuration at the first work station 134, it is contemplated that the cup-shaped blank could be formed to a different configuration at the first work .station.

Once the flat disc 88 has been formed into the cupshaped blank 92, the punch 138 is withdrawn as a stripper pin 154 is extended in a known manner to free the cup-shaped blank from the punch and leave the blank in the die cavity 142, (See FIG. 6.) A knock-out pin 162 is extended to raise the cup-shaped blank 92 upwardly into the transfer opening or chamber 160 in the dial 128. The dial 128 is then indexed to move the cupshaped blank to a second work station 166 (FIG. 8).

At the second work station 166, a second punch 168 is extended to press the hemispherical blank 92 downwardly in a rectangular work or die cavity 172. This causes the blank 92 to move from the position shown in dashed lines in FIG. 8 to the solid line position. The punch 168 has a body portion 170 which is generally rectangular in cross sectional configuration and has a rounded nose portion 171. Therefore, as the hemispherical blank 92 moves downwardly in the die cavity 172, the annular side portion 96 of the blank is cold worked by flat side walls 174 of the work cavity 172 and punch 168 to form the generally

rectangular side panels

102, 104, 106, and 108 (see FIG. 9) on the cups haped blank 92.

The nose 171 of the punch 168 and the bottom of the die cavity 172 have the same configuration as a portion of a hemisphere. Therefore, the blank 92 is plastically deformed in the die cavity 172 so as to have a rectangular upper portion defined by the

side panels

102, 104, 106, and 108 and an arcuate or circular bottom .portion 1 l4.(see FIG. 10). However, it should be noted that the rectangular rim 110 (FIG. 9) and arcuate bottom 114 .of the cup-shaped blank 92are uninterrupted by stress inducing joints or seams which would weaken a wheel lug 36 which is eventuallyformed by further cold working of the cup-shaped blank.

Once work operations at the second station 166 have been completed, the punch 168 iswithdrawn (FIG. 8), a knock-out pin 184 (FIG. 8) is then extended to raise the blank 92 out of the work chamber 172 upwardly into the transfer chamber 160 in the dial 128. The dial 128 is then indexed and the chamber 160 is moved 'over a work cavity 188 (FIG. 11) at a third work station 190.

A punch 192 having a rectangular end portion 194 is then extended to press the blank 92 downwardly into the work chamber 188 to cold work the circular bottom portion 114 of the blank 92 (see FIG. 9) into the rectangular configuration of FIGS. 11 and 12. Thus, a flat rectangular leading end surface 189 of the punch 192. forms a flat rectangular inner surface 200 on the blank 92 and a flat rectangular outer surface 202. In doing this, metal is forced or extruded into the side panel 108 to extend the side panel upwardly (as viewed in FIG. 11). Also, a rectangular inclined connector section 206 is formed between the flat bottom panel 118 and the generally rectangular side panel 108.

Once the blank 92 has been formed to the configuration of FIG. 12 in the work cavity 188 by the punch 192, a stripper pin 210 is extended as the punch 192 is withdrawn from the work cavity 188. A knock-out pin 220 is then extended to push the blank 92 from the work cavity 188 upwardly into the receiving chamber 160 in the dial. The dial is then indexed again to position the blank 92 over a work cavity or chamber 224 at the fourth work station 216 (FIG. 13).

A punch 228 is then lowered to press the cup-shaped blank 92 downwardly into the work chamber 224 to further form the

rectangular side panels

102, 104, 106, and 108 and the rectangular bottom panel 118. In addition, the connector section 206 is forced against a stamp element 232 to impress or stamp indicia 233 (FIG. 2) on the connector section 206 indicating that the rectangular panel 108 is to be located adjacent to the hub of the wheel assembly 20; The word WHEEL is stamped on the connector section 206 by the stamp element 232 and indicates that the rectangular panel 108 is to be the hub or wheel clamp panel 66 of the wheel lug 36. In addition, a second stamp element 234 stamps or impresses the word RIM on the bottom panel 118 of the blank 92 to indicate that the rectangular panel 104 is to be the rim clamp panel 64 (see FIGS. 2 and 4) of the wheel lug 36.

Once the cup-shaped blank 92 has been cold worked and stamped at the fourth work station 216, the part-is elevated by knock-out pin into the dial 160 and again indexed to move the'blank 92 to a fifth or piercing station 238 (see FIG. .14). A piercing punch 240 then pierces a hole 122 in the bottom panel 118 of the blank 92. The hole 122 (FIGS. 2 and'4) is oblong and is'defined by a pair of semi-circular end surfaces 241 and 243 interconnected by a rectangular section 244 to enable the lug 36 to be positioned relative to the bolt 32.

Once the blank 92 has been pierced, it is moved to the sixth and final work station 248 by the transfer dial 160. At the final work station 248, the cup-shaped blank 92 is given the configuration of the wheel lug 36 by a pair of dies 252 and 254 located in a work cavity 256. At this station the relatively long side panel 108 of the cup-shaped blank 92 is curved inwardly with the radius (see FIG. 4) .to form the hub or wheel panel 66 of the wheel lug 36. Similarly, the panel 104 of the cup-shaped blank 92 is curved outwardly with the radius 78 to form the rim panel 64 of the wheel lug 36. It should be noted that thetwo generally

rectangular panels

104 and 108 of the cup-shaped blank 92 are also inclined at the same acute angle relative-to the bottom portion 1 18 of the cup-shaped blank at the work station 248 to shape these surfaces for abutting engagement with the clamp surfaces 40 and 42 on the rim 22 and hub 26 (see FIGS. 1 and 3).

The foregoing method of making the wheel lug 36 is particularly advantageous in that the wheel lug is formed with a continuous wall 84 made up of the pancould be transmitted by the wheel lug 36 without failure.

In view of the foregoing description, it can be seen that the wheel lug 36 is made by forming a flat circular disc 88 into a cup-shaped blank which is then cold worked at successive work stations to form a relatively strong wheel lug having a continuous or uninterrupted wall 84 made up of a plurality of panels. One of these panels, that is the rim clamp panel 64, is convexly bowed outwardly to provide for intimate abutting engagement between the generally rectangular outer surface of this panel and the clamp surface 40 on the wheel rim 22. Similarly, the wheel or hub clamp panel 66 is concave or bowed inwardly to enable the generally rectangular outer surface of this panel to be disposed in abutting engagement throughout its length and width with the clamp surface 42 on the hub 26 (FIG. 3).

Having described a specific preferred method and embodiment of the present invention, the following is claimed:

1. A method of making a metal wheel lug for use in securing a removable tire carrying rim to the hub of a wheel assembly, said method comprising the steps of providing a flat metal blank having a continuously curving outer edge circumscribing an imperforate center portion of the blank, forming a cup-shaped blank having an uninterrupted rim which is free of joints and having a continuously curving cross-sectional configuration in a plane extending perpendicular to a central axis of the cup-shaped blank at a location disposed between the uninterrupted rim and bottom portion of the cup-shaped blank by plastically deforming the flat blank at a temperature below the crystallization temperature of the metal of the flat blank, plastically deforming the bottom portion of the cup-shaped blank to a generally flat rectangular configuration at a temperature below the crystallization temperature of the metal of the cup-shaped blank, plastically deforming side portions of the cup-shaped blank at a temperature below the crystallization temperature of the cup-shaped blank to form four generally rectangular sides extending transversely to the bottom portion of the cup-shaped blank, said step of plastically deforming side portions of the cup-shaped blank to form four generally rectangular sides including the maintaining of an uninterrupted and joint free rim on the cup-shaped blank, and plastically deforming an opposing pair of the rectangular sides of the cup-shaped blank to slope inwardly toward each other in a direction away from the bottom portion of the cup-shaped blank at a temperature below the crystallization temperature of the metal of the cup-shaped blank to adapt one of the pair of rectangular sides for engagement with the rim of the wheel assembly and the other of the pair of rectangular sides for engagement with the hub of the wheel assembly.

2. A method as set forth in claim 1 wherein the steps of plastically deforming bottom and side portions of the cup-shaped blank includes the step of plastically flowing metal from the bottom portion of the cup-shaped blank to one side portion of the cup-shaped blank to extend the one side portion of the cup-shaped blank further from the bottom portion of the blank than the other side portions of the cup-shaped blank.

3. A method as set forth in claim 1 further including the method step of piercing the bottom portion of the cup-shaped blank to provide an opening for receiving a fastener to secure the wheel lug to the wheel assembly.

4. A method as set forth in claim 1 wherein said step of forming a cup-shaped blank includes the step of plastically deforming the flat metal blank into a cup-shaped blank having a configuration which is generally hemispherical.

5. A method as set forth in claim 4 wherein said step of forming a cup-shaped blank further includes the step of plastically deforming the generally hemispherical cup-shaped blank to form four side portions extending outwardly from a continuously curving bottom portion and defining a rectangular rim of the cup-shaped blank.

6. A method as set forth in claim 1 wherein said step of plastically deforming an opposing pair of the rectangular sides includes bowing said other side inwardly with a first radius of curvature to shape said other side for engagement with a curved surface on the hub of the wheel assembly.

7. A method as set forth in claim 6 wherein said step of deforming an opposing pair of the rectangular sides further includes the step of bowing said one side outwardly with a second radius of curvature which is greater than said first radius of curvature to shape said one side for engagement with the rim of the wheel assembly.

8. A method of making a metal wheel lug for use in securing a removable tire carrying rim to the hub of a wheel assembly, said method comprising the steps of providing a flat circular metal disc, forming a cupshaped blank having a circular rim and the configuration of a portion of a sphere by plastically deforming the disc at a temperature below the crystallization temperature of the metal of the disc, plastically deforming a bottom portion of the cup-shaped blank to a generally flat rectangular configuration at a temperature below the crystallization temperature of the metal of the cupshaped blank, plastically deforming a side portion of the cup-shaped blank at a temperature below the crystallization temperature of the cup-shaped blank to form four intersecting sides extending transversely to the bottom portion of the cup-shaped blank, and plastically deforming an opposing pair of the sides of the cupshaped blank to adapt one of the pair of sides for engagement with the rim of the wheel assembly and the other of the pair of sides for engagement with the hub of the wheel assembly by bowing said one side outwardly with a first radius of curvature to shape said one side for abutting engagement with a curved surface of the rim of the wheel assembly and bowing said other side inwardly with a second radius of curvature to shape said other side for abutting engagement with a curved surface of the hub of the wheel assembly.

9. A method as set forth in claim 8 wherein the steps of plastically deforming bottom and side portions of the cup-shaped blank includes the step of plastically flowing metal from the bottom portion of the cup-shaped blank to said other side portion of the cup-shaped blank to extend said other side portion of the blank further from the bottom portion of the cup-shaped blank than said one side portion of the cup-shaped blank.

10. A method as set forth in claim 8 further including the method steps of stamping first indicia adjacent to said one side of the cup-shaped blank indicating that said one side of the cup-shaped blank is adapted for engagement with the rim of the wheel assembly and stamping second indicia adjacent to said other side of providing a flat circular metal disc, forming a cupshaped blank having a circular rim and the configuration of a portion of a sphere by plastically deforming the disc at a temperature below the crystallization temperature of the metal of the disc, plastically deforming a bottom portion of the cup-shaped blank to a generally flat rectangular confuguration at a temperature below the crystallization temperature of the metal of the cupshaped blank, plastically deforming a side portion of the cup-shaped blank at a temperature below the crystallization temperature of the cup-shaped blank to form four intersecting sides extending transversely to the bottom portion of the cup-shaped blank, plastically deforming an opposing pair of the sides of the cup-shaped blank to adapt a first one of the pair of sides for engagement with the rim of the wheel assembly and a second one of the pair of sides for engagement with the hub of the wheel assembly, said steps of plastically deforming bottom and side portions of the cup-shaped blank includes the step of plastically flowing metal from the bottom portion of the cup shaped blank to one of said first and second sides of the cup-shaped blank to extend this side of the blank further from the bottom portion of the cup-shaped blank than the other one of the pair of sides.

13. A method of making a metal wheel lug for use in securing a removable tire carrying rim to the hub of a wheel assembly, said method comprising the steps of providing a flat circular metal disc, forming a cupshaped blank having a circular rim and the configuration of a portion of a sphere by plastically deforming the disc at a temperature below the crystallization temperature of the metal of the disc, plastically deforming a bottom portion of the cup-shaped blank to a generally flat rectangular configuration at a temperature below the crystallization temperature of the metal of the cupshaped blank, plastically deforming a side portion of the cup-shaped blank at a temperature below the crystallization temperature of the cup-shaped blank to form four intersecting sides extending transversely to the .bottom portion of the cup-shaped blank, and piercing the bottom portion of the cup-shaped blank to provide an opening for receiving a fastener to secure the wheel lug to the wheel assembly.

14. A method of making a metal wheel lug for use in securing a removable tire carrying rim to the hub of a wheel assembly, said method comprising the steps of providing a flat circular metal disc, forming a cupshaped blank having a circular rim and the configuration of a portion of a sphere by plastically deforming the disc at a temperature below the crystallization temperature of the metal of the disc, plastically deforming a bottom portion of the cup-shaped blank to a generally flat rectangular configuration at a temperature below the crystallization temperature of the metal of the cupshaped blank, plastically deforming a side portion of the cup-shaped blank at a temperature below the crystallization temperature of the cup-shaped blank to form four intersecting sides extending transversely to the bottom portion of the cup-shaped blank, and bowing one of said sides inwardly with a first radius of curvature to shape said one side for engagement with a first curved surface on the wheel assembly.

15. Amethod as set forth in claim 14 further including the step of bowing another of said sides outwardly with a second radius of curvature which is greater than said first radius of curvature to shape said other side for engagement with a second curved surface on the wheel assembly.

Claims

1. A method of making a metal wheel lug for use in securing a removable tire carrying rim to the hub of a wheel assembly, said method comprising the steps of providing a flat metal blank having a continuously curving outer edge circumscribing an imperforaTe center portion of the blank, forming a cup-shaped blank having an uninterrupted rim which is free of joints and having a continuously curving cross-sectional configuration in a plane extending perpendicular to a central axis of the cup-shaped blank at a location disposed between the uninterrupted rim and bottom portion of the cup-shaped blank by plastically deforming the flat blank at a temperature below the crystallization temperature of the metal of the flat blank, plastically deforming the bottom portion of the cup-shaped blank to a generally flat rectangular configuration at a temperature below the crystallization temperature of the metal of the cup-shaped blank, plastically deforming side portions of the cup-shaped blank at a temperature below the crystallization temperature of the cupshaped blank to form four generally rectangular sides extending transversely to the bottom portion of the cup-shaped blank, said step of plastically deforming side portions of the cup-shaped blank to form four generally rectangular sides including the maintaining of an uninterrupted and joint free rim on the cupshaped blank, and plastically deforming an opposing pair of the rectangular sides of the cup-shaped blank to slope inwardly toward each other in a direction away from the bottom portion of the cup-shaped blank at a temperature below the crystallization temperature of the metal of the cup-shaped blank to adapt one of the pair of rectangular sides for engagement with the rim of the wheel assembly and the other of the pair of rectangular sides for engagement with the hub of the wheel assembly.

8. A method of making a metal wheel lug for use in securing a removable tire carrying rim to the hub of a wheel assembly, said method comprising the steps of providing a flat circular metal disc, forming a cup-shaped blank having a circular rim and the configuration of a portion of a sphere by plastically deforming the disc at a temperature below the crystallization temperature of the metal of the disc, plastically deforming a bottom portion of the cup-shaped blank to a generally flat rectangular configuration at a temperature below the crystallization temperature of the metal of the cup-shAped blank, plastically deforming a side portion of the cup-shaped blank at a temperature below the crystallization temperature of the cup-shaped blank to form four intersecting sides extending transversely to the bottom portion of the cup-shaped blank, and plastically deforming an opposing pair of the sides of the cup-shaped blank to adapt one of the pair of sides for engagement with the rim of the wheel assembly and the other of the pair of sides for engagement with the hub of the wheel assembly by bowing said one side outwardly with a first radius of curvature to shape said one side for abutting engagement with a curved surface of the rim of the wheel assembly and bowing said other side inwardly with a second radius of curvature to shape said other side for abutting engagement with a curved surface of the hub of the wheel assembly.

10. A method as set forth in claim 8 further including the method steps of stamping first indicia adjacent to said one side of the cup-shaped blank indicating that said one side of the cup-shaped blank is adapted for engagement with the rim of the wheel assembly and stamping second indicia adjacent to said other side of the cup-shaped blank indicating that said other side of the cup-shaped blank is adapted for engagement with the hub of the wheel assembly.

11. A method as set forth in claim 8 further including the method step of piercing the bottom portion of the cup-shaped blank to provide an opening for receiving a fastener to secure the wheel lug to the wheel assembly.

12. A method of making a metal wheel lug for use in securing a removable tire carrying rim to the hub of a wheel assembly, said method comprising the steps of providing a flat circular metal disc, forming a cup-shaped blank having a circular rim and the configuration of a portion of a sphere by plastically deforming the disc at a temperature below the crystallization temperature of the metal of the disc, plastically deforming a bottom portion of the cup-shaped blank to a generally flat rectangular confuguration at a temperature below the crystallization temperature of the metal of the cup-shaped blank, plastically deforming a side portion of the cup-shaped blank at a temperature below the crystallization temperature of the cup-shaped blank to form four intersecting sides extending transversely to the bottom portion of the cup-shaped blank, plastically deforming an opposing pair of the sides of the cup-shaped blank to adapt a first one of the pair of sides for engagement with the rim of the wheel assembly and a second one of the pair of sides for engagement with the hub of the wheel assembly, said steps of plastically deforming bottom and side portions of the cup-shaped blank includes the step of plastically flowing metal from the bottom portion of the cup-shaped blank to one of said first and second sides of the cup-shaped blank to extend this side of the blank further from the bottom portion of the cup-shaped blank than the other one of the pair of sides.

13. A method of making a metal wheel lug for use in securing a removable tire carrying rim to the hub of a wheel assembly, said method comprising the steps of providing a flat circular metal disc, forming a cup-shaped blank having a circular rim and the configuration of a portion of a sphere by plastically deforming the disc at a temperature below the crystallization temperature of the metal of the disc, plastically deforming a bottom portion of the cup-shaped blank to a generally flat rectangular configuration at a temperature below the crystallization temperature of the metal of the cup-Shaped blank, plastically deforming a side portion of the cup-shaped blank at a temperature below the crystallization temperature of the cup-shaped blank to form four intersecting sides extending transversely to the bottom portion of the cup-shaped blank, and piercing the bottom portion of the cup-shaped blank to provide an opening for receiving a fastener to secure the wheel lug to the wheel assembly.

14. A method of making a metal wheel lug for use in securing a removable tire carrying rim to the hub of a wheel assembly, said method comprising the steps of providing a flat circular metal disc, forming a cup-shaped blank having a circular rim and the configuration of a portion of a sphere by plastically deforming the disc at a temperature below the crystallization temperature of the metal of the disc, plastically deforming a bottom portion of the cup-shaped blank to a generally flat rectangular configuration at a temperature below the crystallization temperature of the metal of the cup-shaped blank, plastically deforming a side portion of the cup-shaped blank at a temperature below the crystallization temperature of the cup-shaped blank to form four intersecting sides extending transversely to the bottom portion of the cup-shaped blank, and bowing one of said sides inwardly with a first radius of curvature to shape said one side for engagement with a first curved surface on the wheel assembly.

15. A method as set forth in claim 14 further including the step of bowing another of said sides outwardly with a second radius of curvature which is greater than said first radius of curvature to shape said other side for engagement with a second curved surface on the wheel assembly.