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 metallurgical transport vehicle factory in Xuancheng, Anhui, has long been responsible for transferring high-load loads within its plant area. Its transport wheels are frequently replaced under high temperature, heavy load, and dusty conditions, seriously affecting production line continuity. When the factory was searching for alternatives to wheel forgings, it encountered the challenge of universal parts on the market being difficult to match with special workstation dimensions and performance.
Original cast wheels exposed three major problems during use: first, insufficient wheel surface hardness, causing premature wear loss at the contact points with the track; Second, fatigue cracks develop at the connection between the hub and spokes due to repeated impact, resulting in high maintenance frequency; Third, the individual weight is relatively large, increasing overall vehicle energy consumption and steering resistance. The plant's annual unplanned downtime losses due to wheel failure exceed 8% of the estimated capacity, making it urgent to produce forgings that combine strength, toughness, and wear resistance.
To address these pain points, Jianing Forging offers customized wheel forging solutions. First, select specific grades of alloy steel bars, and by controlling the forging ratio and final forging temperature, ensure that the internal fiber structure is continuously distributed along the direction of force, improving the fatigue life of the casting by about 40%. Second, the rim and tread undergo medium-frequency quenching treatment, achieving a surface hardness of HRC 48-52, while the core remains highly tough, effectively resisting impact deformation. At the same time, based on the manufacturer's actual track width and axle load parameters, the hub wall thickness and the radius of the spokes transition arc were optimized, reducing the weight of a single piece by 7% without lowering load capacity. Finally, each forging comes with a full-size inspection report, facilitating interchangeability and eliminating the need for additional modifications after installation. After delivery, the factory's wheel replacement cycle was extended from the previous 3 months to 8 months, reducing annual comprehensive maintenance costs by about 30%.
Made with alloy steel with custom composition, normalized + tempered pretreatment, yield strength ≥ 550MPa, impact toughness ≥ 45J/cm², suitable for heavy loads and complex stress conditions.
Multi-station closed die forging process allows the wheel flange, hub, and spokes to be forged in one go, with dimensional tolerances controlled at ≤±0.5mm, reducing subsequent machining allowance.
The tread and rim are quenched by induction heating, resulting in a hardened layer depth of 3~5mm, uniform surface hardness, retaining internal plasticity, and suppressing delamination and cracking.
Each product is printed with a traceability code, recording raw material furnace batch numbers, forging parameters, heat treatment curves, and final inspection data, facilitating on-site tracking and management.
Φ400mm~Φ800mm (customizable according to workstation), wheel width 80~160mm, suitable for track models 38kg/m~60kg/m.
The single-wheel static load rating is ≥80kN, with a dynamic load safety factor of ≥1.5, suitable for metallurgical transport vehicles with a load ≤ 40 tons.
Tread hardness HRC 46~52, core hardness HB 220~260, meeting the requirements for a balance of wear resistance and toughness.
Depending on the outer diameter and wheel width, a single piece weighs 30kg~120kg, which is 5%~8% lighter than castings of the same size.
