Research on the Wear Behavior of the Fixed Cone Liner of a Cone Crusher Based on the Discrete Element Method

Constant Wear Criterion for Optimization of the Crushing Chamber of Cone Crushers

The crushing chamber is the core component of a cone crusher, consisting of mantle and concave parts. Reducing the impact of crushing chamber wear on the performance of cone crushers and the quality of crushed products while extending the service life of the mantle and concave has become a significant research challenge. The impact of the compression ratio and particle size distribution coefficient on the particle crushing pressure is investigated here in order to establish the particle pressure model. The effect of the normal and tangential components of particle crushing pressure on the wear of the mantle and concave is discussed, and the wear with the increase in crushed products and accumulation of operating time is explored in order to develop a wear model of the crushing chamber. By evaluating the compensation of the worn crushing chamber according to the adjustment mechanism of the mantle, a constant wear criterion for the crushing chamber of the cone crusher is proposed. Through analysis of industrial experimental data on an experimental prototype of a ZS200MF cone crusher with an optimized mantle and concave, the capacity was found to fluctuate at 83.45 t/h with no apparent downward trend, the calibration size production was reduced by 6.2%, and the wear similarity coefficient was 8.82%. This indicates that replacing the optimized mantle and concave based on the constant wear criterion maintains the performance of the cone crusher, delays the decline in the quality of the crushed products, and ensures similarity between the adjusted worn crushing chamber and the initial crushing chamber, which verifies the feasibility and effectiveness of the constant wear criterion for the optimization of crushing chamber. Based on the constant wear criterion, cone crushers can be optimized to obtain a crushing chamber with constant wear characteristics, which provides theoretical support for the development of new high-efficiency cone crushers as well as the optimization of existing equipment.

Hardening by Transformation and Cold Working in a Hadfield Steel Cone Crusher Liner

This paper presents the characterization of a secondary cone crusher concave liner made of Hadfield steel used in Chilean mining after crushing copper minerals during all service life. During use, a cone crusher concave liner suffers indentation (cold working) and abrasion; this combination provides the concave with a layer that constantly renews itself, maintaining a surface highly resistant to abrasive wear. The results presented here were obtained using optical microscopy, microhardness test, measuring abrasion using the dry sand/rubber wheel apparatus, and x-ray diffraction peaks analysis through the classic Williamson–Hall method. After analysis of results, two hardened surfaces have been found—one a product of heat treatment and the other due to deformation during use. This work proposes ways to explain them; the first one uses a thermodynamic model to calculate stacking fault energy, and the second compares the liner with cold-rolled samples.