400 Ton Truck Axle

Preliminary Concepts: Industrial team and fabricator reimagine truck component

DCI’s industrial team worked with a fabricator to develop preliminary design concepts for a 400 ton haul truck axle box which developed cracks early in the truck’s life, causing major shut downs at a coal mine. DCI went to the site to study a decommissioned axle box and to understand the demands of the trucks. Based on data gathered, DCI developed designs with basic geometry and material quantities for the fabricator to price and propose to the mine. With this information, the client could evaluate the ROI on designing and fabricating a new axle vs. the cost of ongoing maintenance with the existing axles.

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Sheridan, Wyoming
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Project Highlights

  • DCI performed preliminary analysis and recommended design details and welding procedures.
  • DCI developed a 3D Solid Works model to verify crack location and fatigue stress concentrations.
  • DCI implemented detailing to increase fatigue performance.

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