Carbon Fiber Prepreg Layup Inspection
Use a laser positioning system to verify the carbon cloth layer angle (±1° tolerance) and check whether there are wrinkles, impurities or uneven resin distribution in each layer of carbon fiber cloth. Unqualified products must be immediately discontinued and preforms must be scrapped.
Mould Closing Pressure Test
Before hot high pressure curing, use pressure sensitive film to detect the mold closing state. If the pressure distribution area exceeds 5%, the mold needs to be readjusted to ensure that the thickness tolerance of the wheel rim section after molding is ±0.2mm.
Rims geometry inspection
Use a laser 3D scanner to scan the molded wheel rim in full size and compare the design model data:
Wheel rim radial runout tolerance: road wheels <0.2mm, mountain wheels <0.2mm
Axial runout tolerance: road wheels <0.2mm, mountain wheels <0.2mm
Out-of-tolerance products need to enter the correction process, and will be scrapped if the correction fails three times.
Brake Surface Flatness Inspection
Use a precision marble platform with a micrometer to test:
The flatness of the brake surface of the road wheel is ≤0.1mm
The flatness of the brake surface of the mountain wheel is ≤0.15mm
At the same time, use a coating thickness gauge to verify the thickness of the brake edge wear-resistant coating (standard value 150±20μm)
Dynamic Balance Test
Tested on a dedicated balancing machine at rated speed (300rpm):
Dynamic balance value of road wheels ≤5g·cm
Dynamic balance value of mountain bike wheels ≤8g·cm
Out-of-tolerance products need to be adjusted by counterweighting. The counterweight points shall not exceed 3 and the total weight shall be ≤3g.
Hole Symmetry Detection
Hole angle deviation ≤0.5°
Adjacent hole spacing tolerance ±0.15mm
Symmetrical hole center deviation ≤0.3mm. Holes that exceed tolerance can be refilled, but no more than 2 holes can be refilled on the same circle.
Ultrasonic Non-destructive Testing
Interface bonding strength ≥ 85MPa
Bubble defect area < 0.5mm2
Delamination defect length <2mm
Unqualified products will be directly scrapped.
Resin Penetration Uniformity Verification
Use industrial CT to scan key sections and check the resin impregnation rate:
The volume content of carbon fiber must reach 55-65%
Porosity <1.5%
Three pieces are randomly sampled from each production batch for destructive testing.
Weight Consistency Test
The weight difference of wheels in the same batch is ≤15g
The deviation between the measured weight and the design value is ≤2%
Overweight products need to be processed again, but the wall thickness must not be lower than the safety threshold.
Comprehensive Performance Test Report
Each product will generate an independent test report, including:
Radial/axial stiffness test data
Impact test record (25kg drop hammer 1m height)
X-ray non-destructive testing certificate