Production Process of PC200 Excavator Idler Wheels

1. Raw Material Procurement and Quality Inspection

    

   High-strength steel suitable for the application shall be selected for the core components (wheel body, bushing, and main shaft) of the idler wheel: the wheel body is generally made of high-hardenability cast steel (e.g., ZG35CrMo) or high-quality structural steel (e.g., 40Mn2); the bushing is mostly made of copper alloy or bimetallic composite material; the main shaft is made of alloy structural steel such as 42CrMo.
   After entering the factory, raw materials shall be subject to spectral analysis, hardness testing, flaw detection and other methods to verify whether the material composition and purity meet the design standards, and raw materials with defects such as sand holes, cracks, and slag inclusions shall be rejected.
2. Wheel Body Forming and Processing

    

   The mainstream forming processes are divided into forging and casting, among which the forging process is more suitable for the PC200 idler wheels used in high-load working conditions:
   • Forging Process: Heat the steel billet to 1100–1200℃, and perform integral die forging forming by a die forging press, so as to densify the internal metal grains of the wheel body and improve its strength and fatigue resistance; after forging, conduct trimming and straightening to remove flash and burrs and ensure the dimensional accuracy of the wheel body shape.
   • Casting Process: Pour molten steel into the mold, and demold after cooling; however, castings are prone to internal air holes, so additional aging treatment is required to eliminate internal stress.
   Some manufacturers adopt the roll forging and welding process, i.e., first roll forging the rim and hub, then splicing them by welding, but the overall performance is weaker than that of integral forging.
3. Precision Machining

    

   The formed wheel body shall be finish-machined by CNC equipment to ensure assembly accuracy:
   • Carry out turning and boring on the inner hole, mounting hole position and rim working surface of the wheel body to ensure that the roundness and coaxiality of the inner hole meet the tolerance requirements (usually the tolerance is controlled within ±0.05mm).
   • After quenching and tempering (quenching + high-temperature tempering) of the main shaft, perform turning and grinding to ensure the surface roughness and dimensional accuracy of the main shaft and improve the matching degree with the bushing.
   • The bushing shall be subject to boring and rolling to enhance the wear resistance of the inner wall.
4. Key Heat Treatment Procedures

    

   Heat treatment is the core step determining the wear resistance of the idler wheel, mainly targeting the wheel body working surface and main shaft:
   • Wheel Body Surface Quenching: Adopt medium-frequency induction hardening technology to locally quench the working surface of the rim in contact with the crawler, so that the surface hardness reaches HRC58–62, and the core maintains toughness (HRC25–30) to avoid wear and edge chipping during operation.
   • Low-temperature Tempering: Conduct low-temperature tempering at 180–220℃ after quenching to eliminate quenching stress and prevent wheel body cracking.
   • Main Shaft Heat Treatment: After quenching and tempering, the surface hardness of the main shaft can reach HRC28–32, which has both strength and toughness to meet the load-bearing requirements.
5. Sealing and Bearing Assembly
   • First, press-fit the processed bushing into the inner hole of the wheel body to ensure a firm interference fit without loosening.
   • Install the sealing assembly: The PC200 idler wheel mostly adopts a double-seal structure of double-lip seal ring + labyrinth seal. Insert the seal ring into the sealing groove of the wheel body to prevent sand, mud and water vapor from invading the internal bearings.
   • Press-fit the main shaft, inject lithium-based grease to ensure the lubrication effect when the bearing rotates; finally assemble the end cover to complete the overall assembly.
6. Finished Product Inspection and Factory Delivery

    

   After assembly, the product shall undergo multi-dimensional inspection before leaving the factory:
   • Dimensional Inspection: Use calipers, micrometers, coordinate measuring machines to detect the outer diameter of the wheel body, inner hole size and mounting hole spacing to ensure compatibility with the chassis of PC200 excavators.
   • Performance Testing: Manually rotate the idler wheel to test its rotation flexibility, which is qualified if there is no jamming or abnormal noise; conduct hydraulic pressure sealing test to verify the sealing performance and prevent oil leakage.
   • Non-destructive Testing: Detect hidden cracks inside the wheel body and main shaft through magnetic particle inspection or ultrasonic flaw detection.
   • Coating and Rust Prevention: After passing the inspection, perform shot blasting derusting on the surface of the idler wheel, then spray anti-rust primer and special topcoat for engineering machinery, and mark the specifications, models and production batch numbers.