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 truck factory in Xilin Gol, Inner Mongolia, has long been engaged in the assembly of large mining dump trucks. Its wheel components operate under high-load and heavy gravel conditions in open-pit mining areas for extended periods, which places strict requirements on the strength, fatigue resistance, and wear resistance of forgings. During the wheel forging selection process, the mining truck factory experienced frequent equipment downtime and high maintenance costs due to issues such as insufficient product lifespan and poor batch stability. After multiple rounds of technical evaluation and field testing, the plant ultimately chose to cooperate with Jianing Forging, which customizes wheel forgings for them to support continuity and safety in mining transportation operations.
The core pain points faced by the mining truck factory include: First, the service life of wheel forgings under heavy load, impact, and high temperature conditions is far below design expectations, with some forgings developing fatigue cracks after 300 hours of operation; Second, dimensional tolerances and mechanical properties fluctuate greatly across different batches of forgings, requiring frequent rework during assembly and affecting production line efficiency; Third, suppliers respond slowly, with emergency replenishment cycles exceeding 15 days, forcing mining truck factories to accumulate large amounts of safety inventory, occupying funds and storage resources. In addition, the complex road conditions in mining areas and the severe wear caused by stone splashing caused severe wear on the wheel hub surface. Traditional heat treatment processes struggled to balance hardness and toughness, further increasing the risk of component failure.
To address these pain points, Jianing Forging provides systematic solutions from four aspects: material selection, forging processes, subsequent heat treatment, and quality control systems:
1. Material End: Uses alloy structural steel treated with controlled sulfur and phosphorus, combined with microalloying technology, enhancing strength while improving low-temperature impact toughness, allowing forgings to maintain stable performance even in environments as low as -40°C.
2. Process Side: Implementing multi-directional die forging forming processes, optimizing pre-forging and final forging die designs to continuously distribute metal flow lines along the wheel hub's stress direction, thereby improving fatigue life; After forging, a graded quenching and tempering process is used to obtain fine-grain tempered sorbitite structure, with hardness uniformity controlled within the HRC±1.5 range.
3. Dimensional accuracy: Introduces online hot-state dimensional inspection and mold temperature closed-loop control technology to stabilize dimensional tolerances in key forging parts within IT8 level, achieving interchangeability between batches without the need for secondary repairs.
4. Delivery Capability: Established a dedicated emergency response mechanism for mining areas, reducing the lead time for regular orders to 7 working days, and urgent orders to complete production scheduling within 48 hours, helping customers reduce inventory pressure.
