Analysis of the difference in wear characteristics and material performance selection between the rolling bowl wall and the crushing wall of a cone crusher

During the operation of the cone crusher, the rolling bowl wall (fixed cone liner) and the crushing wall (moving cone liner) together form the crushing chamber, but there are significant differences in their working state, force mode, and wear mechanism. Scientific material selection needs to be based on a deep understanding of these differences, balancing key performance indicators such as toughness, hardness, and fatigue resistance in a targeted manner.

1、 Analysis of Differences in Wear Characteristics

Main motion forms of components, core stress and wear mechanisms, typical failure modes

The broken wall (dynamic cone lining plate) undergoes eccentric pendulum motion around the centerline to withstand high-frequency, medium strength impacts and compressions. The material is repeatedly meshed and bent in the crushing chamber, and the surface of the lining plate experiences cyclic stress. The wear is relatively uniform, but accompanied by significant impact fatigue effects. Impact fatigue peeling and uniform wear. Failure often manifests as the formation and propagation of microcracks in the surface material due to fatigue, resulting in small pieces peeling off.

The rolling bowl wall (fixed cone lining plate) is relatively fixed and stationary, mainly subjected to continuous compression and material sliding friction (especially in the parallel zone). The material slides along the surface of the lining plate under its own gravity and dynamic cone compression, resulting in strong abrasive wear. The wear pattern is prone to form more severe uneven distribution in the lower part. High stress abrasive wear and localized groove wear. The main manifestation of failure is the "thinning" of the material rather than peeling off.

2、 Material performance indicators focus on selection

Based on the above differences, the performance emphasis of the two in material selection is different.

1. Material selection focus for broken wall (dynamic cone lining plate)

Impact toughness (AK value): This is the primary consideration for material selection. The broken wall must be able to absorb high-frequency impact energy and prevent brittle fracture or large-scale peeling when subjected to dynamic loads. Therefore, the material needs to have a high reserve of impact toughness.

Work hardening ability and fatigue resistance: Under high-frequency cyclic stress, materials not only require surface hardening to resist wear, but also their sub surface structure needs to have good resistance to fatigue crack initiation and propagation. Good work hardening ability can ensure an increase in surface hardness during use.

Recommended material direction: High toughness high manganese steel (such as Mn18Cr2, Mn22Cr2) is a common choice due to its excellent impact toughness, work hardening ability, and inherent fatigue resistance. Under extreme impact conditions, improved ultra-high manganese steel with higher toughness can be considered.

2. Focus on material selection for rolling bowl wall (fixed cone liner)

High initial hardness and compressive strength: To resist continuous compression and cutting of materials, the rolling bowl wall material should have a high initial surface hardness (such as HRC 40 or above) and compressive yield strength to slow down abrasive wear rate.

Wear resistance and uniformity of microstructure: Under sliding friction dominated wear, the macroscopic and microscopic hardness uniformity, carbide morphology and distribution of materials have a significant impact on wear resistance. A fine and uniform organization helps provide consistent wear resistance.

Moderate toughness: It is necessary to ensure that no brittle fracture occurs under compressive stress, but the requirement for impact toughness is usually lower than that of the fractured wall.

Recommended material direction: Medium high carbon alloy steel (such as 40CrMnMo, etc.) or high toughness high chromium cast iron composite materials are directions worth considering. They provide acceptable toughness while offering high initial hardness. If possible, local reinforcement design can be applied to areas with faster wear and tear in the lower part.

3、 Consideration of pairing and comprehensive economy

Design concept of equal lifespan: In an ideal state, the wear life of the dynamic and fixed cone liners should be close to each other, so as to replace them synchronously and reduce the number of shutdowns. This usually means that more wear-resistant (possibly more expensive) materials need to be selected for the mill bowl walls with faster wear rates, or the toughness of the broken walls needs to be fully guaranteed to avoid unexpected early failure.

Cost benefit analysis: When selecting, the evaluation should be based on the cost of processing one ton of ore. Although the unit price of the rolled bowl wall may be higher, if its longer lifespan can effectively extend the overall replacement cycle, it may have better overall economy.

Adaptation and adjustment of working conditions:

When processing extremely hard and highly abrasive ores, the requirements for hardness and wear resistance of the rolling mill wall should be further improved.

When dealing with large, high impact ores, the toughness requirements of the fractured wall should be the primary consideration.

4、 Conclusion

The material selection of the bowl wall and crushing wall of the cone crusher follows different performance logics:

The fractured wall (dynamic cone liner) should focus on high impact toughness, good fatigue resistance, and work hardening ability to cope with dynamic loads, and prioritize preventing fracture and peeling failure.

The rolling bowl wall (fixed cone liner) should focus on high initial hardness, compressive strength, and uniform wear resistance to resist continuous compression and sliding abrasive wear.

In practical applications, there is no universal material solution. The most suitable choice is to combine the specific abrasion and impact characteristics of the ore, equipment operating parameters, and cost structure. Through scientific evaluation and testing, materials with matching performance focuses are configured for both, and the coordination of their lifespans is pursued to achieve the comprehensive goal of safe, efficient, and economical operation. Collaborating with suppliers with strong material engineering capabilities is an effective way to achieve this goal.