The basis of my question really comes down to the fundemantal question: If a wheel manufacturer offers multiple offsets for the same wheel, (+4mm, +10mm, +15mm....etc) where does the material come from to provide the different offsets?
As I look at it there are only a couple of options:
1) to optomize cost they cast one base casting, with excess material on the center section, and during the machining clean up phase they machine the various offsets that they plan to offer to the market. This would optomize their casting set up cost and would give them the greatest flexibility during the manufacturing process.
2) the second option is to determine through FEA analsis what the minimum center section would be to handle the stress any more importantly the cycle loads, then cast evey wheel to that dimension. But if they did that they would have relocate the wheel spokes on every wheel to position the backface to the proper offset location. In other words. If they offer a +4mm offset wheel (like Rota) and a +10mm offset wheel, the spokes of the +10mm wheel would have to be moved in by an additional +6mm to generate the additional offset.
When I look at the various wheels on the market, I don't get the impression that the spokes are moving. So this leads me to believe the wheel manufactures are utilizing option (1). So if I machine an additional +6mm, I'm not violation any of the original design considerations and therefore not risking a "wheel-off". I'm just taking the same material they would have taken during the original machining process.
So where is the material coming from?