How to Improve the Wear Resistance of Feeder Breakers
A feeder breaker is a type of equipment used in industries such as coal and mining, particularly in open-pit mining. It serves as an integrated mining machine for crushing, feeding, and conveying materials. A persistent challenge with equipment in the mining industry is wear resistance, as it directly affects the service life of feeder breakers and the overall operational costs of the mining industry.
We typically adopt the following methods to enhance the wear resistance of feeder breakers:
Ⅰ. Adding Wear-Resistant Liners to Material-Contacting Parts of Crushing and Conveying Units
Wear-resistant liners made of high-manganese steel are installed in areas where materials come into contact with the crushing and conveying units.
Composition and Properties: High-manganese steel (primarily composed of manganese) undergoes rapid work hardening on its surface under strong impact and extrusion. This allows the core to retain the good toughness and plasticity of austenite, while the hardened surface layer exhibits excellent wear resistance.
Advantages:
High Wear Resistance: Effectively resists material erosion and friction, prolonging equipment life and reducing maintenance and replacement costs.
Impact Resistance: Withstands impact loads during material transportation, ensuring liners do not detach or crack under harsh conditions.
Heat Resistance: Some liners maintain stable performance in high-temperature environments, meeting the wear-resistant requirements of hot equipment.
Corrosion Resistance: Certain liners offer rust and corrosion resistance, suitable for working environments with corrosive media.
Processability: Can be easily cut, drilled, bent, or rolled, allowing customized fabrication according to equipment shapes and sizes, with convenient installation and replacement.
Ⅱ. Special Material and Heat Treatment for Crushing Teeth in the Toothed Crushing Unit
The crushing teeth in the feeder breaker’s toothed crushing unit are precision-cast from a special formula material and undergo heat treatment, offering high strength, good toughness, and resistance to both wear and impact.
Technical Parameters: With a hardness of HRC 46–52 and a crushing strength of up to 200 MPa, the uniquely designed teeth feature a deep spiral distribution, enhancing material-gripping ability, block formation rate, and production efficiency while minimizing over-crushing.
Service Life: Verified by cases, their lifespan (over 3 years) far exceeds the industry average (0.5–1.5 years).
Installation and Structure:
High-Frequency Heating Assembly: Ensures firm and reliable fixation, completely solving issues of tooth detachment or spline wear.
Hammer-Type Crushing Unit: The movable tooth heads in the hammer crushing unit feature advanced tooth profiles and fixing methods, including surfacing wear-resistant materials or integral casting with wear-resistant microalloys, ensuring long service life.
Material and Processing:
Tooth head fixing seats: Made of ZG310-570 steel, with tooth plate fixing grooves machined by CNC gantry milling.
Tooth roller shafts and fixing seats: Fabricated via integral forging using 40Cr or 42CrMo steel.
Clamping blocks: Precision-machined on grinders after heat treatment, with inclined angles processed using precision fixtures.
Quality Control: Our company strictly adheres to a “pursuit of excellence” policy in material selection and processing, ensuring precision manufacturing.
Ⅲ. Structural Design of the Conveying Box
The feeder breaker’s conveying box is composed of multiple small conveying boxes arranged in a straight line, serving to connect the head and tail of the machine and support the sliding of conveying chains to transport materials.
Manufacturing Process:
Constructed from Q345 steel plates via welding, with a robust structure.
Surface treatment: Shot blasting before cutting, stress relief after welding, followed by shot peening and painting to ensure quality and appearance.
Wear-Resistant Liners: Internal liners are made of wear-resistant plates, secured by bolts for quick and easy replacement.
The above measures to enhance the wear resistance of feeder breakers effectively reduce damage caused by hard materials, extending the equipment’s service life and improving operational efficiency in mining applications.
