Specific Damage Caused To The Lining Plate by Improper Feeding Method

The feeding method of the cone crusher, including the uniformity of feeding, the distribution of material flow, and the control of feeding amount, is one of the key factors affecting the service life of the lining plate (rolling bowl wall and crushing wall). When the feeding method is improper, such as uneven feeding, segregation, or excessive feeding amount, it can cause a series of specific damages to the lining plate. This article is based on on-site practice and fault analysis, systematically sorting out the main hazards of improper feeding to lining plates.

1、 Causing excessive force on one side of the lining plate

The most direct consequence of improper feeding is causing excessive stress on one side of the lining plate. When the feeding device is not installed properly, or when the material fed into the crushing chamber fails to disperse evenly on the distribution tray, the material will concentrate on one side of the crushing chamber.

This phenomenon of partial load causes the broken lining plate to bear significantly higher loads on one side than other parts. Under continuous impact and compression, the wear rate of the lining plate on the side with greater force is significantly accelerated, resulting in localized excessive wear. Research has shown that if the material inside the crushing chamber cannot be fully filled around, it will cause the cone to experience eccentric force, which will further exacerbate the wear of the lining plate.

Unilateral force not only accelerates wear, but may also cause more serious equipment failures. For example, feed eccentricity can lead to uneven force distribution on the moving cone, intensifying equipment vibration, and even causing cone crusher flying cone phenomenon in severe cases.

2、 Causing uneven wear on the upper and lower parts of the lining plate

The uneven distribution of feeding particle size is closely related to improper feeding methods, which can lead to uneven wear of the lining plate along the height direction.

Severe wear on the upper part: When the feeding particle size is coarse and large pieces of material are concentrated in the crushing chamber, the crushing of the ore mainly occurs in the upper part of the crushing chamber. In this case, the upper lining plate is mainly subjected to impact and compression, resulting in more severe wear, while the lower lining plate is relatively less worn. In actual operation, the motor power is often low, and the service life of the lining plate is shortened.

Severe wear in the lower part: On the contrary, if there is too much fine-grained material in the feed (such as more than 10%) and the feed is not properly distributed, the crushing of the ore mainly occurs in the lower part of the crusher. At this time, the lower lining plate is severely worn, while the upper part is less worn. This uneven wear will gradually reduce the feeding port, ultimately affecting the throughput and output of the crusher.

In any case, irregular wear of the lining will cause changes in the geometric shape of the crushing chamber, affecting the laminated crushing effect and further exacerbating the wear process.

3、 Causing material flow deviation and wear

The inconsistency between the geometric centerline of the material flow at the feeding port and the centerline of the crusher is a common cause of uneven wear of the lining plate. When the material flow through the feeding port is mainly concentrated in a part of the feeding port cross-sectional area (such as the 2/3 area), the centerline of the conical material pile on the distribution tray does not coincide with the geometric centerline of the material flow.

In this case, the material distribution tray cannot evenly distribute materials according to the crushing chamber, and most of the materials enter the same side of the crushing chamber, causing uneven wear on the rolling bowl wall and the machine body lining. This kind of partial wear has a gradual nature, and once formed, it will further exacerbate the unevenness of the material flow distribution, forming a vicious cycle.

To solve this problem, it is necessary to adjust the position of the feeding port so that the geometric centerline of the material flow passing through the feeding port is basically consistent with the centerline of the crusher, so that the material can be evenly distributed according to the crushing chamber.

4、 Causing overload and blockage damage to the lining plate

Excessive feeding volume or fast feeding speed can cause excessive material accumulation in the crushing chamber, resulting in blockage faults. In a blocked state, the lining plate not only bears normal crushing force, but also additional compression and friction.

The continuous squeezing of blocked materials will cause local stress concentration on the lining plate, accelerating the wear process. In severe blockage situations, if not dealt with in a timely manner, it may lead to cracks or deformation of the lining plate. In addition, blockage can also reduce production efficiency and increase the crushing cost per unit of ore.

The correct feeding method requires that the ore be evenly dispersed in the crushing chamber through the distribution tray, and the fed ore should not be higher than the level of the rolling mill wall. The feeding size should also be controlled within a reasonable range, usually requiring the maximum size of the feeding block not to exceed 85% of the feeding port size.

5、 Formation of feed segregation causing local wear

Feed segregation refers to the separation of materials with different particle sizes or densities during the feeding process, resulting in uneven distribution of materials in the crushing chamber. For example, large pieces of material are concentrated on one side, small pieces of material are concentrated on the other side, or hard materials are separated from soft materials.

The practice of H-type hydraulic cone crusher has shown that when the feeding cannot achieve uniform distribution of ore in the crushing chamber through the ore tray, it will cause the fixed cone liner to be worn off center. Once the lining plate is worn off center, there will be significant fluctuations in power and hydraulic pressure due to uneven force during crushing, which will affect the stable operation of the equipment.

To address this issue, improvement measures can be taken on the production site, such as optimizing the ore distribution method in the ore bin, or setting up dead corners at the bottom of the crushing chamber to allow the ore to enter the crushing chamber after secondary distribution, in order to achieve relatively uniform ore distribution.

6、 Intensify the chain reaction of other faults

Improper feeding methods can indirectly cause or exacerbate other faults related to lining plates:

Increased risk of liner loosening: Excessive unilateral force can cause a more concentrated distribution of impact loads on the liner. When the fixing strength of the locking bolt or clamping ring is insufficient, it is more likely to cause liner loosening.

The risk of cone cracking increases: Poor feeding can cause large fluctuations in the operating pressure of the crusher, and the cone is frequently impacted. Especially in situations such as feed eccentricity, large amounts of material, and uneven feed particle size, the force point will change from multi-directional balanced force to unidirectional local force, increasing the risk of cracking in the dynamic cone.

Upper jumping of crusher: Uneven or excessive feeding of ore is one of the reasons for the upper jumping of the crusher. This abnormal jumping not only affects the crushing effect, but also generates additional impact loads on the lining plate.

7、 Response measures in production

The following measures can be taken to address the damage caused to the lining plate by improper feeding methods:

Ensure uniform distribution of feed: Ensure that the ore is fed in the middle of the distribution tray, so that the material is evenly dispersed around the crushing chamber through the distribution tray.

Optimize the feeding port position: Adjust the feeding port position to make the geometric centerline of the material flow basically consistent with the centerline of the crusher, reducing eccentric wear.

Control the particle size composition of the feed: By pre screening, the particle size distribution of the feed is made reasonable, avoiding the concentration of too large or too fine materials entering.

Implementing crowding feeding: When conditions permit, maintaining continuous and stable crowding feeding helps to form stable laminated crushing, making the lining plate relatively evenly stressed.

Improvement of feeding device: Improve the feeding funnel to avoid material blockage and segregation.