Why Forging Is the Key to Longer-Lasting Undercarriage Parts

When it comes to heavy machinery, especially for Cold Milling Machines, the undercarriage bears the brunt of the workload. Every excavation, road paving, milling, or construction project relies on these components to maintain stability and performance under extreme conditions. Among the various alloy manufacturing methods, forging stands out as a game-changer for creating durable and long-lasting undercarriage parts. But what exactly makes forging superior, and how does it contribute to the longevity of these critical components?

In the process of asphalt milling/ micro milling, existing asphalt is carefully removed to create a smoother surface for new paving. This process requires stable traction and movement, emphasizing the importance of robust undercarriage parts.

Let’s dive into the benefits of forging and why it’s the preferred method for premium undercarriage parts.

Why Using Superior Undercarriage Parts Important

Asphalt milling machines are engineered to endure the rigors of the job, but even the most robust machines can experience significant wear and tear. The rotating milling drum, which is responsible for grinding the existing surface with road milling teeth, exerts substantial stress on the undercarriage components. Additionally, the continuous movement of the machine and the weight of the milling drum can cause wear on the tracks, rollers, and other critical undercarriage parts. No one can reject the advanced road construction method when the use of reclaimed asphalt pavement (RAP) in road milling processes further enhances sustainability and cost-effectiveness, making it a preferred choice in modern road construction and maintenance. This wear and tear can compromise the efficiency and effectiveness of the milling machine, necessitating frequent maintenance and part replacements.

This is why choosing high-quality undercarriage parts is so important. Reliable components are better equipped to handle the stress and demands of various asphalt milling projects, ensuring consistent performance, minimizing downtime, and reducing long-term maintenance costs. By investing in durable undercarriage parts, you can maximize the efficiency and lifespan of your milling machine, even in the toughest working conditions.

I. Why Forged Undercarriage Parts Outlast the Competition

Undercarriage components produced using alternative methods, such as casting, may initially seem cost-effective but often fail to deliver long-term durability. Cast parts can contain hidden flaws, such as porosity or uneven material distribution, making them more susceptible to cracking or wear under heavy loads, especially when dealing with damaged surface asphalt.

In contrast, forging ensures that every component is built to withstand the toughest conditions. This durability translates into fewer replacements, lower maintenance costs, and less downtime—ultimately saving contractors time and money.

Addressing the pavement surface is crucial in the milling process to remove damaged layers from asphalt surfaces and prepare it for repaving, ensuring a smooth and even surface that enhances durability and performance.

II. The Science Behind Forging

Forging is a manufacturing process where metal is heated and shaped under high pressure, making it ideal for applications such as cold planing. This method rearranges the material's internal grain structure, eliminating voids or weaknesses and aligning the grains to flow in the direction of the stresses the part will face during operation.

Compared to casting or welding, forging creates parts that are significantly stronger, tougher, and more resistant to wear.

III. How Forging Physically Improves Performance of Final Product

Forging works by applying high pressure to shape heated metal into a specific form, which fundamentally changes the material's internal structure to make it stronger and more durable. Here’s an easy way to understand it:

1. Metal Grain Flow: Imagine the grain structure of metal as tiny fibers, like the threads in a piece of fabric. In a forged part, these "fibers" are compressed and aligned to follow the shape of the part. This alignment reinforces the material and helps it resist forces like bending, twisting, or breaking during use.
2. Eliminating Weak Points: In cast or welded parts, tiny gaps or inconsistencies can form, like bubbles or cracks in the material. These act as weak points that can lead to failure under stress. Forging, however, compresses the metal, eliminating these gaps and creating a dense, uniform structure.
3. Increased Toughness: By compressing and shaping the metal under high pressure, forging improves its ability to absorb shock and resist wear. This means that undercarriage parts, like track chains and rollers, can better withstand the constant pounding, high pressures, and abrasion that come with heavy machinery operations.

In simpler terms: forging reshapes the metal at the microscopic level to make it tougher and more unified. The end result? Parts that can handle extreme conditions and last much longer than those made using other methods.

IV. Forging and Advanced Heat Treatment Through ABP Equipments: The Perfect Combination

By combining forging with the advanced heat treatment equipments, manufacturers can achieve unparalleled control over the internal structure of the material. This process fine-tunes the metal’s hardness, strength, and toughness, ensuring every component meets the exact demands of every part of heavy machinery operations. Additionally, the large cold milling machines have wider milling width are heavier, particularly the drum width of over 2000mm, required a superior crawler parts. 

Together, forging and advanced heat treatment creates undercarriage parts that are not only stronger but also more durable and reliable, delivering unmatched performance in the harshest conditions.

V. Key Benefits of Forging for Undercarriage Parts

1. Superior Strength: Forged parts are inherently stronger than those made using casting or machining processes. The forging process refines the grain structure of the metal, making it denser and less prone to cracks or fractures. For undercarriage parts like track chains, rollers, and sprockets, this means greater resistance to the intense pressures and impacts they endure on the road surface of the job site.

2. Enhanced Wear Resistance: Undercarriage components are constantly subjected to abrasive conditions, whether it’s from rocky terrain, heavy loads, or repetitive movements. Forged parts offer superior wear resistance because of their dense and uniform material structure. This helps prevent premature wear and deformation, extending the lifespan of components.

3. Improved Fatigue Resistance: Heavy machinery operates in cycles of loading and unloading, which can lead to material fatigue over time. Forged parts are better equipped to handle these repetitive stresses due to their grain alignment, reducing the risk of fatigue-related failures. This makes forged parts especially valuable for components like track chains and pin holes, which are prone to stress concentration.

4. Greater Impact Toughness: Forged components have exceptional toughness, meaning they can absorb sudden shocks and impacts without cracking. This is particularly important for parts like idlers and track rollers, which encounter frequent jolts during operation on uneven or harsh terrain.

5. Uniform Material Integrity: Forging eliminates internal voids or porosity, common issues in casting. This ensures that the material is consistent throughout the component, reducing weak points that could lead to premature failure. A uniform material structure also improves the part’s ability to distribute loads evenly, minimizing localized stress points.

VI. Choosing Forged Parts: A Long-Term Investment

While forged undercarriage parts may have a slightly higher upfront cost than cast alternatives, the long-term benefits far outweigh the initial investment. The extended lifespan, reduced maintenance needs, and improved performance of forged parts contribute to significant cost savings over the life of the machine.

Pavement milling, which involves the removal of the  layer of various paved structures, is a process that can benefit from the durability and efficiency of forged parts. By adjusting the milling machine based on the project conditions, operators can ensure effective milling and better assess the current surface condition.

Everpads makes every undercarriage parts with forging method, It's time to upgrade your machine.