The Shanxi Jianing Forging Forging Train Wheel, Mine Overhead Wheel, and Heavy-Duty Overhead Wheel Forging Project features mature forging technology for high-strength wheels, excellent load-bearing performance, and suitable for heavy-duty conditions in rail transit and mines.
A mining vehicle factory in Rizhao, Shandong, has long been engaged in the manufacturing and maintenance of mining transportation equipment. Its wheel forgings, as key components of the vehicle's walking system, directly affect the safety and operational efficiency of the entire vehicle. During mass production, the factory frequently encountered issues such as early wheel wear, wheel flange cracking, and insufficient assembly precision, which led to higher maintenance costs and delayed schedules, severely restricting capacity growth. To this end, the plant sought to collaborate with suppliers with mature forging process capabilities to improve wheel quality from the source.
1. Short service life: The average service life of original wheel forgings under heavy-load, rocky road conditions is less than 6 months. Frequent replacement not only increases material costs but also causes unplanned downtime.
2. Poor dimensional consistency: Different batches of forgings show significant deviations in key dimensions such as wheel diameter and rim thickness, requiring repeated grinding during assembly, which affects production efficiency.
3. Multiple internal defects: The forging has loose structure, microcracks, and other defects inside, making it prone to brittle fracture under impact loads and posing safety hazards.
4. Unstable heat treatment: Uneven hardness distribution leads to premature local wear and a high overall scrap rate.
Jianing Forging provides customized wheel forging solutions tailored to the specific working conditions of this mining vehicle plant:
1. Material Selection: Made with alloy structural steel, rigorously inspected and controlled by composition helps maintain substrate purity and reduces internal defects at the source.
2. Fine forging process: Using multi-directional die forging technology combined with a closed die design, it effectively refines grains, eliminates looseness, and increases the density of forgings.
3. Precise dimensional control: Using CNC machining centers for high-precision mold trimming, batch forgings maintain stable dimensional tolerances and can be assembled directly without secondary processing.
4. Heat Treatment Optimization: Based on the mine's characteristics of heavy loads and low speeds, a specialized quenching + tempering process is developed to achieve hardness uniformity within HRC 3, improving wear resistance and impact toughness.
Through these measures, after using Jianing's forged wheel forgings, the mill's average wheel service life was extended to 18 months, assembly efficiency improved by about 30%, and shutdown accidents caused by wheel issues dropped by 90%. The two parties have established a long-term stable supply partnership and are developing new forging specifications for future models.
