Due to the harsh environment of the construction machinery, the engineering rim is subjected to a large force. Therefore, the rim of the general engineering vehicle is made of high-strength thick steel plate, the thickness of the steel plate is 10-16 mm, and multiple pieces are separately formed and welded together. Conventional forming requires heating, which can cause problems such as energy waste, air pollution, surface scale defects, and reduced efficiency. Therefore, how to improve production efficiency, energy saving and environmental protection, and reduce costs are the primary technical issues in the engineering wheel industry.

Traditional engineering rim forming process

The traditional engineering rim forming process is to cut the large plate into strips, rolls, and weld the billet into a cylinder, and then hot press forming, through metal processing, assembly, and welding into a rim. It is characterized by a single piece of hot-pressed parts that are assembled and welded. Heat forming causes waste of energy, low efficiency, and surface defects caused by hot pressed scale. The hot formed workpiece is shown in Figure 1.


Figure 1 hot pressing workpiece


Energy saving and environmental protection forming process

Different from the traditional process, the energy-saving and environmentally-friendly forming process changes the hot press forming into a group of cold rolling forming (see Figure 2), and then metal processing, assembly, and welding into rims. The process is characterized in that two parts are grouped at the same time by cold rolling forming, and then cut into two workpieces, thereby improving production efficiency, and there is no surface defect caused by scale, thereby achieving the purpose of energy saving.


Figure 2 Group of cold rolling parts

Economic Benefit Analysis


The traditional engineering rim uses a hot press forming process, which is pressed by a hydraulic press and heated by electricity or natural gas. For example, a medium-frequency electric furnace with a power of 500 kW can produce up to 30 pieces per hour and a production capacity of 240 pieces. After the combination of the two pieces, it is only equivalent to 120 sets of wheels, and the heating cost per piece is about 16 yuan, 32 yuan per set. With group cold rolling forming technology, the output of the class can reach 400 sets, the efficiency is increased by more than three times, and heating is not required, the surface quality is good, and the grinding is reduced. China produced about 300,000 loaders in 2011 and needed more than 1.2 million sets of wheels. If each set saves 32 yuan, it can save 38.4 million yuan a year.

This cold-rolling process has been widely used in the commercial vehicle wheel and passenger car wheel industry. However, since the engineering wheel rim is too thick, the requirements for the weld processing and the cold rolling type equipment are relatively high, so the relative investment is relatively large. Hot pressing is easy to form, investment is small, the threshold for entering the manufacturing field is low, and the application is extensive, but it does not conform to the concept of energy saving, environmental protection and green manufacturing.

Conclusion

The successful development of this group of cold rolling production technology has brought a technological revolution of energy saving and environmental protection to the engineering wheel industry. The process of producing multi-piece engineering wheels by group cold rolling forming process is feasible, efficient, energy-saving and environmentally friendly, which will bring huge economic benefits to the wheel industry and is the future development trend of the engineering wheel industry.

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