simens Yaylı Konik Kırıcı

Upper Frame: A cast steel (ZG270-500) structure with a cylindrical shape, supporting the fixed cone and adjustment mechanism. Its inner wall is processed with a tapered surface to match the fixed cone liner, and the top is connected to the feeding hopper. The thickness of the frame wall is 30-80mm, and radial reinforcing ribs are designed to resist the crushing force.

Lower Frame: A heavy-duty cast steel (ZG35CrMo) base that bears the weight of the entire equipment and the reaction force during crushing. It is fixed on the foundation with anchor bolts and internally accommodates the eccentric shaft sleeve, main shaft bearing, and lubrication system.

Moving Cone: The core working part, consisting of a cone body and a wear-resistant liner. The cone body is forged from 42CrMo alloy steel, with a spherical bottom that fits with the spherical bearing of the main shaft to ensure flexible swing. The liner is made of high-chromium cast iron (Cr20) or manganese steel (ZGMn13), which is fixed on the cone body by pouring zinc alloy to ensure close contact.

Fixed Cone (Concave): An annular liner installed on the inner wall of the upper frame, usually composed of 3-6 segments for easy replacement. The material is the same as the moving cone liner, and its inner surface is designed with a specific taper (15°-30°) and tooth shape to form a crushing cavity with the moving cone.

Eccentric Shaft Sleeve: A cast steel (ZG35CrMo) sleeve with an eccentric bore, which is the key part to drive the moving cone to swing. Its eccentricity (5-20mm) determines the swing amplitude of the moving cone, and the outer surface is equipped with a large bevel gear.

Bevel Gear Pair: Including a small bevel gear (mounted on the input shaft) and a large bevel gear (fixed on the eccentric shaft sleeve), made of 20CrMnTi alloy steel with carburizing and quenching treatment to ensure wear resistance and transmission accuracy.

Main Shaft: A forged alloy steel (40CrNiMoA) shaft, with the upper end connected to the moving cone and the lower end inserted into the eccentric bore of the eccentric shaft sleeve. It transmits the torque and crushing force, with a diameter of 80-300mm depending on the model.

Discharge Port Adjustment Device: Composed of an adjustment ring, support ring, and hydraulic cylinder (for hydraulic cone crushers) or a handwheel (for spring cone crushers). Rotating the adjustment ring can change the height of the fixed cone, thereby adjusting the discharge port size (5-50mm).

Safety Device: Spring group (for spring cone crushers) or hydraulic cylinder (for hydraulic cone crushers). When uncrushable materials enter the crushing cavity, the safety device is triggered to expand the discharge port, discharge the foreign matter, and then reset automatically to protect the equipment.

Lubrication System: An independent thin oil lubrication system with oil pump, cooler, and filter, which delivers lubricating oil (ISO VG 46) to the main shaft bearing, eccentric shaft sleeve, and gear pair to reduce friction and control temperature (≤60℃).

Dustproof Device: Labyrinth seal and oil seal are used between the moving cone and upper frame, and some models are equipped with air purge system (0.3-0.5MPa) to prevent dust from entering the lubrication system.

Pattern Making: According to the design drawings, wooden or metal patterns are made, with a shrinkage allowance of 1.2-1.5% to compensate for the volume reduction during casting solidification.

Molding: Resin-bonded sand is used to make the mold, and the cavity is coated with a refractory coating (zirconium oxide) to improve the surface quality of the casting. Cores are used to form internal cavities such as oil passages.

Melting and Pouring:

The raw materials are melted in an induction furnace, and the temperature is controlled at 1520-1560℃. For ZG35CrMo, chromium and molybdenum are added to adjust the chemical composition (Cr: 0.8-1.2%, Mo: 0.2-0.3%).

The molten steel is poured into the mold at 1480-1520℃, and the pouring speed is controlled to avoid turbulence and inclusions.

Heat Treatment: After casting, normalization (880-920℃, air cooling) is performed to refine the grain, then tempering (550-600℃) to eliminate internal stress, and the hardness is controlled at HB 180-220.

Pattern and Molding: Precision foam patterns are used to ensure the accuracy of the eccentric bore. Shell molding is adopted, which has high dimensional accuracy and good surface finish.

Pouring and Heat Treatment: The molten steel is poured at 1500-1540℃. After casting, quenching (850℃, oil cooling) and tempering (580℃) are carried out to obtain a tempered sorbite structure, with hardness HB 220-260 and tensile strength ≥785MPa.

Billet Heating: The steel billet is heated to 1150-1200℃ in a gas furnace to ensure sufficient plasticity.

Forging: Open-die forging is used, with multiple upsetting and drawing processes to form the conical shape and spherical bottom, ensuring that the metal grain flow is consistent with the stress direction.

Heat Treatment: Quenching (840℃, water cooling) and tempering (560℃) are performed to achieve a hardness of HRC 28-32, tensile strength ≥900MPa, and good toughness.

Rough Machining: Use CNC milling machine to process the flange surface and reinforcing ribs, removing the casting skin and leaving a machining allowance of 2-3mm. Boring machine is used to process the bearing seat, with dimensional tolerance IT8.

Precision Machining: Grind the flange mating surface to flatness ≤0.1mm/m and surface roughness Ra1.6μm. Drill and tap the bolt holes (M20-M50) with thread tolerance 6H, and ensure the positional accuracy of the holes (±0.1mm).

Turning: CNC lathe is used to process the outer circle and eccentric bore, with a machining allowance of 0.5-1mm left. The eccentricity is measured with a dial indicator to ensure it meets the design requirements (±0.05mm).

Grinding: Grind the outer circle and eccentric bore to dimensional tolerance IT6, surface roughness Ra0.8μm. Process the keyway and gear mounting surface, ensuring the perpendicularity between the gear surface and the axis ≤0.02mm/100mm.

Turning: Process the outer circle, step, and end face on a CNC lathe, leaving a grinding allowance of 0.3-0.5mm.

Heat Treatment: Quenching and tempering to ensure the hardness and toughness.

Grinding: Grind the journal surface to dimensional tolerance IT5, surface roughness Ra0.4μm. Process the thread and keyway, ensuring the thread accuracy 6g.

Rough Machining: Use CNC milling machine to process the outer surface of the moving cone liner and the inner surface of the fixed cone liner, leaving a machining allowance of 1-2mm.

Precision Machining: Grind the working surface to ensure the taper tolerance (±0.05°) and surface roughness Ra3.2μm. Process the mounting holes to ensure they match the cone body or upper frame.

Material Testing:

Use a spectrometer to analyze the chemical composition of cast and forged parts, ensuring they meet the requirements of the material standard (e.g., ZG35CrMo: C 0.32-0.40%, Mn 0.5-0.8%).

Perform tensile test and impact test on the test pieces to check the mechanical properties, such as 42CrMo forging: yield strength ≥785MPa, impact energy ≥60J/cm².

Dimensional Inspection:

Use coordinate measuring machine (CMM) to inspect key dimensions, such as the eccentricity of the eccentric shaft sleeve, the taper of the moving cone, and the position of the bolt holes.

Use a laser scanner to detect the profile of the crushing cavity formed by the moving cone and fixed cone, ensuring it matches the design.

Non-Destructive Testing (NDT):

Ultrasonic testing (UT) is used to detect internal defects in castings (frames, eccentric shaft sleeves), and defects with a diameter >3mm are rejected.

Magnetic particle testing (MPT) is used to inspect the surface and near-surface defects of forgings (main shaft, moving cone body), and cracks >1mm are rejected.

Performance Testing:

Empty Load Test: Run the equipment without load for 2-4 hours, check the rotation of the rotor, the temperature of the bearing (≤70℃), and whether there is abnormal noise.

Load Test: Crush standard materials (e.g., granite) for 8-12 hours, check the production capacity, discharge particle size distribution, and wear of the liners. The product particle size should meet the design requirements (e.g., 5-20mm), and the liners should have uniform wear.

Safety Test:

Simulate the entry of uncrushable materials (e.g., iron blocks) to test the response of the safety device, ensuring it can expand the discharge port in time (≤2 seconds) and reset accurately after discharging the foreign matter.