Energy-saving manufacturing process for engineering wheel rim

Due to the harsh working conditions of construction machinery, the engineering rim is subjected to significant mechanical stress. As a result, the rims of general engineering vehicles are typically made from high-strength thick steel plates, with thickness ranging between 10-16 mm. These plates are usually cut into individual sections, formed separately, and then welded together. The traditional forming process involves heating, which leads to issues such as energy waste, air pollution, surface scale defects, and lower production efficiency. Therefore, improving production efficiency, reducing energy consumption, and minimizing environmental impact have become key technical challenges in the engineering wheel industry. **Traditional Engineering Rim Forming Process** The conventional method begins by cutting large steel plates into strips, rolling them into cylindrical shapes, and welding them together. The resulting billet is then hot-pressed into the final rim shape through metal forming, assembly, and welding. This process involves single-piece hot pressing, which not only consumes a lot of energy but also results in surface defects caused by oxidation scale. The hot-pressed workpiece is shown in Figure 1.

Figure 1: Hot Pressed Workpiece

**Energy-Saving and Environmentally Friendly Forming Process** In contrast to the traditional approach, the energy-saving and eco-friendly process replaces hot pressing with group cold rolling (as seen in Figure 2). This method allows two parts to be formed simultaneously using cold rolling, then cut into individual components. This significantly improves production efficiency and eliminates surface defects caused by scale. The cold-rolled parts are shown in Figure 2.

Figure 2: Group Cold Rolling Parts

**Economic Benefit Analysis** The traditional hot-pressing method requires the use of hydraulic presses and heating via electricity or natural gas. For example, a 500 kW medium-frequency furnace can produce up to 30 pieces per hour, totaling 240 units daily. However, when two pieces are combined into one set, it equates to only 120 sets. The heating cost per piece is approximately 16 yuan, or 32 yuan per set. With the group cold rolling technology, the output can reach 400 sets per hour, increasing efficiency by more than three times. Since no heating is required, the surface quality is better, and less grinding is needed. In 2011, China produced about 300,000 loaders, requiring over 1.2 million wheel sets. If each set saves 32 yuan, this could result in an annual saving of 38.4 million yuan. Although this cold-rolling technique is already widely used in commercial and passenger vehicle wheels, its application in engineering rims faces challenges due to the thicker material requirements. This demands higher precision in welding and specialized cold rolling equipment, leading to higher initial investment. On the other hand, hot pressing is easier to implement, requires less capital, and has a lower entry barrier, making it more commonly used, though it does not align with modern green manufacturing principles. **Conclusion** The successful development of group cold rolling technology represents a major technological advancement for the engineering wheel industry, offering a more efficient, energy-saving, and environmentally friendly production method. The process of producing multiple engineering wheel parts through group cold rolling is not only feasible but also highly beneficial economically. It is set to become a key trend in the future of the engineering wheel industry, driving sustainable growth and innovation.

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