Tackling High Hardness Ore: Analysis And Countermeasures of Common Problems in Wear Resistant Parts of Crushers

In the crushing and processing of high hardness ores such as granite, basalt, quartzite, etc., equipment is undergoing the most severe tests. As the core of the production line, the performance and stability of its wear-resistant components directly determine the operational efficiency of the crusher. This article will systematically analyze several common problems of wear-resistant parts under high hardness working conditions based on industry practice, and provide professional solutions.

Problem 1: Abnormal Early Fracture - Challenge of Insufficient Resilience

Phenomenon description:

Jaw plates, plate hammers, or rolling bowl walls may fracture or develop large-scale cracks during early use or before reaching their expected lifespan, rather than uniform wear.

Deep root cause analysis:

Mismatch in Impact Resilience: High hardness minerals cause significant impact energy on accessories. If the impact toughness (AKV value) of the accessory material is insufficient to effectively absorb energy through plastic deformation, brittle fracture will occur.

Internal defects exist: shrinkage cavities, sand holes, or microcracks generated during the casting process, which become crack sources under sustained high stress and rapidly propagate.

Structural design stress concentration: Poor design such as small transition corners and sudden thickness changes in accessories can lead to local stresses far exceeding the material yield limit.

Improper installation and use: for example, foreign objects on the base during installation, uneven pre tightening force of fastening bolts, or failure to trigger the over iron protection in a timely manner when the equipment enters an unbreakable object (such as an iron block).

Professional coping strategies:

Scientific material selection: Select materials with higher toughness reserves based on specific equipment and ore characteristics, such as ultra-high manganese steel optimized for heat treatment processes or bimetallic composite materials with good toughness support.

Lean manufacturing: Select suppliers who adopt advanced casting techniques (such as V-casting and lost foam casting) and strictly implement non-destructive testing (such as UT and MT) to ensure a dense and defect free internal structure.

Standardized operation: Strictly follow the equipment manufacturer's operating and maintenance procedures to ensure proper installation, and regularly check the sensitivity of safety devices such as hydraulic iron protection systems.

Problem 2: Rapid wear - the wear resistance is not sufficient to withstand extreme tests

Phenomenon description:

The wear rate of the working surface of the accessories is abnormally fast, and the service life is much lower than that of materials with medium hardness, resulting in rapid changes in product particle size and a decrease in production capacity.

Deep root cause analysis:

Mismatch between material hardness and ore hardness: High hardness ores (with a Mohs hardness of up to 7-8 levels) have extremely severe cutting and chiseling wear on accessories. If the surface hardness (HRC) of the accessory is much lower than the hardness of the ore, wear will accelerate rapidly.

The influence of abrasive components: The high content of hard mineral particles such as quartz in the ore has extremely strong abrasive properties.

Improper working parameters: such as setting the closed edge discharge port too small, resulting in excessive laminated crushing in the lower half of the crushing chamber, exacerbating accessory wear.

Professional coping strategies:

Improve the matching degree between hardness and toughness: Select materials with higher initial hardness such as high chromium cast iron and ceramic composite metals, or use surface hardening treatment technology to enhance the hardness of the working surface.

Optimize cavity type and parameters: Cooperate with equipment suppliers or professional accessory manufacturers to evaluate whether the existing crushing cavity type is optimal, and adjust parameters such as discharge port and feeding speed reasonably to form effective material layer protection.

Question 3: Uneven wear - affecting efficiency and cost

Phenomenon description:

The working surface of the accessories shows uneven wear and groove like wear, resulting in low metal utilization and requiring early replacement, which increases the production cost per unit.

Deep root cause analysis:

Uneven distribution of feed: If the feed deviates from the center of the crushing chamber, it will cause premature wear of one side of the accessory. Excessive content of fine powder in the feed material can prevent the formation of an effective self lining protective layer and exacerbate direct wear.

Poor matching accuracy between accessories and equipment: The dimensional tolerance control of accessories is not strict, and there is a gap between them and basic components such as moving cones and eccentric sleeves, resulting in relative motion during operation and abnormal wear.

The structural design of the accessory itself is unreasonable: it fails to guide the material to form an ideal laminated crushing mode in the cavity.

Professional coping strategies:

Ensure uniform feeding: Use a reliable feeder and install a guide plate or adjust the landing point to ensure that the material is vertically and evenly fed into the center of the crushing chamber.

Ensure the accuracy and fit of accessories: Purchase accessories with strict dimensional tolerances to ensure a perfect fit with the host.

Choose optimized design: Adopt a cavity design improved based on computer flow field and stress analysis to promote uniform wear and enhance overall metal utilization.

Conclusion: Systematic thinking responds to high hardness challenges

Facing high hardness ores, the problem of wear-resistant accessories is often not caused by a single factor. It is a systematic engineering involving materials science, structural mechanics, casting processes, and on-site applications. The most effective way to cope is to cooperate with wear-resistant solution providers with deep technical accumulation and complete quality systems, from precise selection, quality control, standardized installation to scientific maintenance, to build a full process solution, in order to ultimately conquer the toughest challenges and achieve the long-term goal of cost reduction and efficiency improvement.