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.
On the production line of a construction machinery factory in Yichun, Heilongjiang, wheel forgings endure long-term tests of high loads and complex working conditions. The factory's original forgings frequently exhibited fatigue cracks and early wear during use, severely limiting the equipment's continuous operation capability and resulting in persistently high maintenance costs. To improve component reliability, the plant sought cooperation with forging suppliers with mature processes.
Construction machinery wheel forgings must balance relatively high strength and impact resistance, while existing products have shortcomings in material selection and forging processes: on one hand, insufficient material purity leads to internal microcracks; On the other hand, improper matching of post-forging heat treatment process parameters results in uneven grain structure and fatigue life far below design expectations. Additionally, large dimensional consistency fluctuations during batch delivery increase the difficulty and scrap rate of subsequent machining.
To address these pain points, Jianing Forging offers customized forging solutions from two dimensions: material optimization and process innovation. On the raw material side, microalloyed steel grades are used, with strict control over the smelting and degassing process to improve purity from the source; In the forging stage, multi-directional forging and temperature/cooling technology are used to refine grains and eliminate microstructure segregation. At the same time, finite element simulation is introduced to assist mold design to support forging forming accuracy, ultimately achieving improved overall product performance.
Field verification shows that wheel forgings using the new solution showed no cracks in 2 million fatigue tests, and their service life is extended by about 40% compared to the original product. Dimensional tolerances are stably controlled within ±0.3mm, allowing direct assembly without additional machining. The subsequent batch output of this construction machinery factory increased by 15%, and comprehensive operation and maintenance costs dropped by about 20%, with extremely positive customer feedback.
