一.Importance of spare parts for jaw crusher
As an important mining machinery and equipment, jaw crusher plays a key role in mining and building materials industries. And jaw crusher spare parts are crucial to the normal operation and performance of the equipment.
Firstly, the quality of spare parts directly affects the efficiency of the equipment. For example, the jaw plate, as an important crushing part, needs to be made of high-strength manganese steel alloy, which has better abrasion resistance and stronger toughness. If the quality of the jaw plate is poor, it is easy to wear out during the crushing process, which will not only reduce the crushing capacity, but also affect the productivity of the equipment. At the same time, the performance of eccentric shaft, flywheel and other spare parts will also affect the operating speed and stability of the equipment, thus affecting the production efficiency.
Secondly, the quality of spare parts is related to the life of the equipment. High-quality spare parts can better withstand the pressure and wear and tear during the operation of the equipment to extend the service life of the equipment. Take the core parts of the jaw crusher as an example, the use of high wear-resistant materials to produce the core parts can ensure its wear resistance, reduce the probability of failure and reduce equipment maintenance costs.
In short, the importance of jaw crusher spare parts should not be ignored. High-quality spare parts can ensure the normal operation of the equipment, improve the efficiency of the equipment, extend the life of the equipment, and bring better economic benefits for the enterprise.
二.Common jaw crusher spare parts
1.Jaw Plate
Jaw plate is divided into movable jaw plate and fixed jaw plate, which is the main wear parts of jaw crusher. The material of the jaw plate has an important influence on its service life and the degree of wear. The common materials of jaw plate are high manganese steel, high chromium cast iron, medium carbon low alloy cast steel and so on. High manganese steel has good impact load resistance, but due to the structure of the crusher, the tension angle between the movable and fixed jaw spanner is too large, which is easy to cause abrasive sliding, the surface hardness of the jaw plate is low due to insufficient deformation hardening, the abrasive material is short-range cutting, and the wear of the jaw plate is fast. In order to improve the service life of the jaw plate, a variety of jaw plate materials have been developed. In addition, also developed in manganese steel, low alloy steel, high chromium cast iron and high manganese steel composite, etc., are in the production of the use of better results.
2.Elbow Plate
The elbow plate has three main functions in the jaw crusher. One is to transmit power, the power transmitted is sometimes even greater than the crushing force; the second is to play the role of insurance, because in the jaw crusher work, the crushing chamber will sometimes fall into the non-crushed material, and damage the equipment, in order to prevent this phenomenon, the elbow plate is used as an insurance piece, when there is non-crushed material into the elbow plate first fracture damage, so as to protect the other parts in the machine does not happen to the phenomenon of damage; the third is to adjust the discharge opening size by replacing different lengths of sizes in some simple pendulum jaw crusher. In some simple pendulum jaw crushers, the size of discharge opening is adjusted by replacing the elbow plate with different lengths. By analysing the role of the elbow plate, it can be seen that when the jaw crusher is in use, the damage of the elbow plate is inevitable, in order to restore the performance of the equipment, it is necessary to replace the elbow plate with a new one. In order to restore the performance of the equipment, it is necessary to replace the elbow plate. Before replacing the elbow plate, you need to choose the appropriate elbow plate, first of all, the elbow plate model needs to be matched with the jaw crusher model, so that it can play a due role in assisting the smooth working process of the machine; secondly, the elbow plate needs to be durable, otherwise in the long term use of the phenomenon of wear and tear will cause a decline in service life, which not only affects the performance of the equipment, but also increase the operating costs.
3.Guards
The guard plate is mainly used to protect the shell of the jaw crusher from abrasion. Different materials have different wear rate on the guard plate, for example, when crushing river pebbles, granite, basalt, iron ore, limestone, quartzite, iron ore, gold ore, copper ore and other materials, the wear rate will be different. When the guard plate is seriously worn or broken, it must be replaced in time. The main materials of the guard plate are manganese-chromium alloy, new composite material, bimetallic composite material, modified high manganese steel and so on. The use of high-quality guard plate, high wear resistance, can better protect the machine, so that the machine to achieve low loss, can effectively protect the body, extend the life of the frame, improve the output of the purpose.
4.Bearings
As long as the lubrication and maintenance is proper, the bearing of the jaw crusher is not easy to be damaged, generally 3 – 5 years of life is no problem. If you choose high-end bearings, high level of processing, maintenance and lubrication in a timely manner, life can be longer. To prolong bearing life, choose the right lubrication system and high quality lubricant, follow the equipment manufacturer’s guidelines, add grease to ensure that sufficient grease enters the critical raceway surfaces, monitor the equipment’s indicator gauges, pay attention to equipment noises or abnormal vibrations, watch for lubricant leaks, and periodically sample the lubricant and check for contamination. After installation, check whether the running parts and fixed parts touch each other, check the radial clearance, and check the tightness of bearings and shoulders.
三.Key factors in the selection of spare parts
1.Considering the impact load
The larger the size of the jaw crusher, the heavier the wear parts will be, and the larger the lump size of the material to be crushed, the greater the impact load to be borne. In this case, the first thing to do is to ensure the toughness of the spare parts material, and improve the hardness under the premise of toughness is guaranteed. For large jaw crusher, modified or diffusion strengthened high manganese steel can be the object of material selection. Its toughness can guarantee the safe operation of the machine, and at the same time can provide enough hardness to cope with the strong impact load. However, for small and medium-sized crushers, the impact loads on the wear parts are not very large, and it is difficult to fully work harden them with high manganese steel.
2.Depending on material composition and hardness
Research shows that when the hardness of the metal material is more than 0.8 times the hardness of the abrasive material, the wear resistance of the material will increase with the increase of the relative hardness. Therefore, when choosing the material of jaw crusher spare parts, the higher the hardness of the material, the higher the hardness requirement of the wear parts. Therefore, under the condition of meeting the toughness requirement, the material with high hardness should be chosen as far as possible. For example, in the crushing of granite and other high hardness materials, you can choose high chromium cast iron and high manganese steel composite material jaw, this material can better resist the wear of the material to extend the service life of spare parts. A mining enterprise, for example, in the crushing of high hardness ore, the use of high chromium cast iron and high manganese steel composite material jaw plate, its service life than ordinary high manganese steel jaw plate increased by nearly double.
Combined with the wear mechanism
The movable jaw plate of the jaw crusher is mainly subject to impact wear, so the toughness should be given priority in the selection of materials; while the fixed jaw plate is mainly subject to cutting wear, so the hardness should be given priority. This can make the movable and fixed jaw plate in different wear mechanism, choose different performance of the material, so as to achieve synchronous operation and improve the overall performance of the equipment. For example, the hardening mechanism of the jaw plate made of medium manganese steel is that the austenite stability decreases after the manganese quantity is lowered, and the austenite is prone to deformation inducing martensitic phase transformation when subjected to impact or abrasion, which improves its wear resistance. For the movable jaw plate, the toughness of medium manganese steel can better withstand impact wear; for the fixed jaw plate, its hardness can also meet the requirements of cutting wear.
四.Ways to extend the life of spare parts
1.Selection of high-quality wear-resistant materials
Jaw crusher spare parts are subjected to great pressure and wear in the operation of the equipment, so the selection of high-quality wear-resistant materials is the key to extend the life of spare parts. For example, for the jaw plate, high manganese steel can be used, such as adding specific elements for modification or diffusion strengthening treatment to improve the initial hardness and yield strength, thus enhancing the wear-resisting ability. When crushing hard materials, high chromium cast iron and high manganese steel composite material is also a good choice, which can better resist the wear of materials. The elbow plate can be made of durable material to ensure that it transmits power and acts as an insurance while reducing wear and tear and lowering operating costs. The guard plate is made of high quality materials such as manganese chrome alloy and new composite materials to improve wear resistance and better protect the machine shell. Bearings choose appropriate lubrication system and high-quality lubricants, colleagues follow the equipment manufacturer’s use of guidelines, good lubrication and maintenance work, to extend the life of bearings.
2.Do a good job of inspection and maintenance
Regular inspection and maintenance of the jaw crusher, timely detection and treatment of problems is an important measure to extend the life of spare parts. The frequency of minor maintenance is generally between half a month and one month, which mainly includes checking and repairing the adjusting device, adjusting the gap of discharge opening, replacing worn liner and thrust plate, repairing and replacing the transmission parts, cleaning the whole machine, re-lubricating oil, repairing and adjusting the lubrication system and so on. Medium repair is generally done once a year, which includes not only all the items of minor repair, but also replacement of worn structures such as tie rods, bushings, thrust plates, etc., turning, grinding and casting inspection of eccentric bearings, and treatment of some bearings. There is no specific time limit for the overhaul, and the main content includes all the items of the medium repair, as well as the replacement of the eccentric shaft of the crusher, reinforcement of the upper part of the connecting rod head with pasteurised alloy, the replacement of all the worn parts, and even the realisation of the technological innovation of the whole crusher and equipment. In addition, it is also necessary to regularly check the wear parts of the crusher, if found serious wear or damage should be replaced in time.
