Systematic practice of selecting, installing, and maintaining wear-resistant accessories for crushers based on working conditions

On the crushing production line, the effectiveness and economic performance of wear-resistant accessories highly depend on a systematic management method closely integrated with specific working conditions. Looking at any aspect of selection, installation, or maintenance in isolation makes it difficult to achieve the goals of reliable operation and cost control. This article will focus on the core of "working conditions" and elaborate on a coherent practical method that covers selection, installation, and maintenance.

1、 Selection Practice: Starting from Accurate Condition Diagnosis

The first step in scientific selection is to comprehensively and quantitatively understand the operating environment, rather than relying on fuzzy experience.

Key dimensions of working condition diagnosis

Material characteristic analysis: This is the foundation. It is necessary to clarify the compressive strength, Mohs hardness, abrasion index (such as Ai value), silicon (quartz) content, moisture and viscosity of the material. For example, materials with high quartz content have much higher cutting wear on accessories than extrusion wear.

Crushing process parameters: including crusher model and cavity design, maximum feed particle size, target discharge particle size, operating speed, rated power and production capacity. Different cavity designs directly affect the material flow path and wear distribution.

Review of historical operational data: Analyze the average service life, failure modes (uniform wear, fracture, peeling), and processing tonnage within the replacement cycle of existing components, providing direct basis for improving selection.

Selection logic that matches the working conditions

Impact resistance requirement: For working conditions such as large block feeding, high drop or high compressive strength, the first priority should be to ensure the high toughness (high impact energy value) of the material, such as choosing ultra-high manganese steel (Mn22Cr2), whose core value lies in resisting fracture and ensuring continuous production.

Anti abrasion requirements: For working conditions with high quartz content and mainly fine-grained grinding, emphasis should be placed on the high initial hardness and microstructure uniformity of the material, and the applicability of medium to high carbon alloy steel or composite materials can be evaluated.

Differentiated configuration strategy: In equipment such as jaw crushers, using different material combinations for components that withstand complex stresses (such as moving jaw plates) and components that withstand stable wear (such as fixed jaw plates) is a common practice to balance safety and economy.

2、 Installation practice: the cornerstone of ensuring design performance

Correct installation is a necessary condition to ensure that accessories reach their expected lifespan and avoid early failure.

Inspection and preparation before installation

Cleaning contact surface: Thoroughly remove dust, rust, old lining residue or burrs from the installation surface of the equipment body and the back of new accessories, ensuring sufficient contact between the two metal surfaces.

Check the accessories and body: verify the dimensions of the accessories and inspect the installation surface of the equipment for any deformation, cracks, or excessive wear. Irregular support surfaces are one of the main reasons for uneven stress and fracture of accessories.

Standardized installation operations

Use the correct tools and methods: Use a torque wrench and tighten the bolts step by step strictly according to the order, torque, and frequency specified by the equipment manufacturer. Random use of pneumatic wrenches may result in uneven tightening force or failure of bolt preload.

Ensure effective support: For large lining plates, the correct use of manufacturer recommended plastic gaskets, zinc alloys, or specialized epoxy resin grout for filling between accessories and the body is a key step in eliminating gaps and providing uniform support.

Tightening after operation: Within the first few hours after the new parts are put into operation, all bolts should be checked and tightened again in the shutdown state to compensate for any looseness that may occur due to initial running in and thermal expansion.

3、 Maintenance Practice: Efficiency Guarantee and Failure Prevention in Operation

Proactive maintenance aims to monitor status, optimize operations, and prevent problems, rather than passively responding to failures.

Operation monitoring and process optimization

Monitor the feeding status: Ensure that the feeding is continuous, uniform, and meets the equipment design specifications. Avoid feed segregation, intermittent or long-term operation beyond specifications, as these can exacerbate abnormal wear.

Maintain reasonable crushing parameters: Set appropriate discharge ports within the allowable range of the equipment according to product requirements. Long term operation under a small discharge port will intensify lamination crushing and accessory grinding, shortening the service life.

Using protective devices: Ensure that the iron remover, metal detector, and equipment's own iron release system are working properly to prevent impact damage to accessories and equipment caused by unbreakable objects.

Preventive inspection and recording

Establish a regular inspection system: Develop an inspection checklist and regularly (e.g. every shift, daily) check the tightening status of accessory bolts, whether wear is uniform, whether there are any abnormal cracks or displacement, and whether equipment vibration and sound are normal.

Measure and record wear data: Periodically measure key wear dimensions (such as jaw plate tooth height, cone crusher liner thickness) and draw wear curves. This helps predict remaining lifespan, plan for planned replacements, and avoid sudden shutdowns.

Failure Mode Analysis: Recording, photographing, and analyzing possible causes (materials, installation, operating conditions, or operations) of any components that experience early failure is an important basis for continuous improvement selection and maintenance strategies.

4、 Closed loop management: Building a continuous improvement process

Connect selection, installation, maintenance, and data feedback to form a complete closed-loop system.

Establish a complete lifecycle file for accessories: record complete information from procurement (materials, suppliers), installation, operation data to final failure.

Regular economic review: Taking the cost of ore processing per ton as the core indicator, compare the long-term performance of different materials and supplier accessories under the same working conditions, and guide future procurement and selection decisions.

Cross departmental collaboration: Promote information sharing between procurement, technology, production, and maintenance departments to ensure that selection decisions consider total operating costs and maintenance practices are fed back into selection criteria.

Conclusion

The management of wear-resistant parts based on working conditions is a dynamic and systematic engineering practice. Its effectiveness is based on a deep understanding of the working conditions, rational selection that matches the working conditions, standardized installation that ensures performance, and proactive maintenance that prioritizes prevention. By implementing this coherent practice, enterprises can control the consumption cost of wear-resistant parts at a reasonable and economical level while ensuring the safe and stable operation of equipment, thereby supporting the continuous improvement of production efficiency and the refined management of operating costs.