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Zhengheng Power Customized Case of Exported Railway Engine Cylinder Heads

The train cylinder head is a core component of the rail transit power system, directly impacting the safety and stability of train operations. The exported train cylinder head project undertaken by Zhengheng Power features multiple unique characteristics compared to traditional cylinder heads: it adopts a single independent assembly mode instead of an integrated design; its structure includes critical orifice holes, water jacket air passages, and special hot spots, with the C-shaped water jacket core experiencing cantilever stress during casting due to buoyancy, resulting in complex operational conditions; it must meet stringent rail transit standards, with precision and positioning requirements far exceeding those of ordinary cylinder heads. These characteristics present numerous challenges, yet the process team confronted 17 core technical difficulties head-on, implemented precise measures, and achieved high-efficiency problem-solving, earning recognition from overseas clients.

Due to special design and operating conditions, this cylinder head is prone to composite issues such as hot spot shrinkage holes, core breakage, and positioning deviations. The customer imposes stringent product standards and tight delivery schedules, placing significant demands on the team’s technical expertise and efficient problem-solving capabilities.
To address challenges such as hot spot shrinkage, core fracture, positioning deviation, and cold iron marks, the Zhengheng Power Special Task Force swiftly traced the root causes and developed targeted solutions: resolving hot spot issues through cold iron technology and temperature adjustment; eliminating core vulnerabilities by optimizing core structure, adding core supports and vent holes; improving precision by adjusting machining allowances and optimizing positioning parameters; and implementing multiple measures to mitigate cold iron marks, effectively overcoming all 17 core bottlenecks.

After repeated debugging and optimization by the team, all 17 challenging issues were resolved. All cylinder heads passed stringent inspections, met the required standards, and were delivered in batches on schedule. The client highly recognized Zhengheng Power’s technical capabilities and response efficiency, laying a solid foundation for future in-depth collaboration.
The success of this project highlights Zhengheng Power’s technological expertise and customization capabilities in the field of high-end casting. The team, guided by problem-solving, optimized processes across multiple dimensions, not only addressing production challenges but also accumulating specialized experience in cylinder head casting. Moving forward, the company will deepen its commitment to process innovation, delivering high-quality powertrain component solutions to global customers.