Technical breakthrough: Solving the problem of high-frequency wear of wear-resistant parts in mine loaders

Solution

1. Material Upgrade: To meet the extreme wear resistance requirements of harsh mining conditions, the Yuezhong Machinery technical team abandoned conventional cast iron and adopted a proprietary high-chromium alloy formula. By adjusting the carbon and chromium ratios and adding strengthening ingredients such as molybdenum and nickel, the material's hardness was increased to over HRC55, resulting in wear resistance more than three times that of conventional parts.

2. Process Optimization: By combining sand casting technology with precise pouring control, and using Flow-3D simulation software to predict the flow trajectory of molten metal, we optimize the pouring and riser design, completely solving defects such as pores and slag inclusions that are common in traditional casting, and ensuring uniform density within the parts. Furthermore, the castings undergo a comprehensive quenching and tempering heat treatment to eliminate internal stress and prevent fractures caused by uneven stress during operation.

3. Strengthening quality control: A full-process quality inspection system has been established, from spectral analysis of raw materials, to real-time monitoring of temperature and weight during the casting process, to hardness testing and non-destructive testing of finished products. Each batch of accessories must undergo 8 inspection processes, and unqualified products are directly rejected.

Project Achievements

- Parts lifespan was extended from 3-5 days to 5-7 days, reducing replacement frequency by 70%. This reduced downtime for maintenance on a single loader by over 120 hours per year.

- The dealer's client's overall equipment operating efficiency increased by 25%, saving over 400,000 yuan annually in parts procurement and maintenance costs alone. The two parties have signed a three-year exclusive supply agreement.