We design, develop and manufacture steel, iron, and bronze wear parts; hydraulic cylinders and nearly any part needed to keep comminution equipment running smoothly. Our offerings include high performance spare parts for most crusher types.
Through the last two decades, we have extended our replacement parts offering to include large-scale open-pit mining equipment, e.g. bushings and pins for hydraulic excavators, electric rope shovels and draglines. Additionally, we now offer customised wide path undercarriages for many models of hydraulic excavators and electric rope shovels.
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When faced with equipment that has specific issues with performance or durability we always begin by applying our knowledge, experience and competencies. Through in-depth failure analysis and destructive testing, we can diagnose any issue. Based on our findings, our team of metallurgical specialists will come up with solutions for any challenge. We are proud of our people and quality centric culture. We know that quality products alone do not make a success. However, combined with dedicated customer support, it makes a world of difference for our customers.
Our high performance parts are backed by our commitment to Quality. We inspect and re-inspect every part that leaves our dock. We know that our parts are used in mission critical equipment and that your success depends on our quality control. Ourstaff of skilled craftsmen strive to make every part perfect in every way. Our strict metallurgical standards in our foundry, our precision turning and machining processes and our inspection department all focus on our customers needs.
From the technician in the foundry pouring castings to the customer support representative taking your order, we are geared toward exceeding your most demanding needs. We build quality and reliability into everything we do.
FLSmidth provides sustainable productivity to the global mining and cement industries. We deliver market-leading engineering, equipment and service solutions that enable our customers to improve performance, drive down costs and reduce environmental impact. Our operations span the globe and we are close to 10,200 employees, present in more than 60 countries. In 2020, FLSmidth generated revenue of DKK 16.4 billion. MissionZero is our sustainability ambition towards zero emissions in mining and cement by 2030.
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A mill is a grinder used to grind and blend solid or hard materials into smaller pieces by means of shear, impact and compression methods. Grinding mill machine is an essential part of many industrial processes, there are mainly five types of mills to cover more than 90% materials size-reduction applications.
Do you the difference between the ball mill, rod mills, SAG mill, tube mill, pebble mill? In the previous article, I made a comparison of ball mill and rod mill. Today, we will learn about the difference between SAG mill vs ball mill.
AG/SAG is short for autogenous mill and semi-autogenous mill, it combines with two functions of crushing and grinding, uses the ground material itself as the grinding media, through the mutual impact and grinding action to gradually reduce the material size. SAG mill is usually used to grind large pieces into small pieces, especially for the pre-processing of grinding circuits, thus also known as primary stage grinding machine. Based on the high throughput and coarse grind, AG mills produce coarse grinds often classify mill discharge with screens and trommel. SAG mills grinding media includes some large and hard rocks, filled rate of 9% 20%. SAG mill grind ores through impact, attrition, abrasion forces. In practice, for a given ore and equal processing conditions, the AG milling has a finer grind than SAG mills.
The working principle of the self-grinding machine is basically the same as the ball mill, the biggest difference is that the sag grinding machine uses the crushed material inside the cylinder as the grinding medium, the material constantly impacts and grinding to gradually pulverize. Sometimes, in order to improve the processing capacity of the mill, a small amount of steel balls be added appropriately, usually occupying 2-3% of the volume of the mill (that is semi-autogenous grinding).
High capacity Ability to grind multiple types of ore in various circuit configurations, reduces the complexity of maintenance and coordination. Compared with the traditional tumbling mill, the autogenous mill reduces the consumption of lining plates and grinding media, thus have a lower operation cost. The self-grinding machine can grind the material to 0.074mm in one time, and its content accounts for 20% ~ 50% of the total amount of the product. Grinding ratio can reach 4000 ~ 5000, more than ten times higher than ball, rod mill.
Ball mills are fine grinders, have horizontal ball mill and vertical ball mill, their cylinders are partially filled with steel balls, manganese balls, or ceramic balls. The material is ground to the required fineness by rotating the cylinder causing friction and impact. The internal machinery of the ball mill grinds the material into powder and continues to rotate if extremely high precision and precision is required.
The ball mill can be applied in the cement production plants, mineral processing plants and where the fine grinding of raw material is required. From the volume, the ball mill divide into industrial ball mill and laboratory use the small ball mill, sample grinding test. In addition, these mills also play an important role in cold welding, alloy production, and thermal power plant power production.
The biggest characteristic of the sag mill is that the crushing ratio is large. The particle size of the materials to be ground is 300 ~ 400mm, sometimes even larger, and the minimum particle size of the materials to be discharged can reach 0.1 mm. The calculation shows that the crushing ratio can reach 3000 ~ 4000, while the ball mills crushing ratio is smaller. The feed size is usually between 20-30mm and the product size is 0-3mm.
Both the autogenous grinding mill and the ball mill feed parts are welded with groove and embedded inner wear-resistant lining plate. As the sag mill does not contain grinding medium, the abrasion and impact on the equipment are relatively small.
The feed of the ball mill contains grinding balls. In order to effectively reduce the direct impact of materials on the ball mill feed bushing and improve the service life of the ball mill feed bushing, the feeding point of the groove in the feeding part of the ball mill must be as close to the side of the mill barrel as possible. And because the ball mill feed grain size is larger, ball mill feeding groove must have a larger slope and height, so that feed smooth.
Since the power of the autogenous tumbling mill is relatively small, it is appropriate to choose dynamic and static pressure bearing. The ball bearing liner is made of lead-based bearing alloy, and the back of the bearing is formed with a waist drum to form a contact centering structure, with the advantages of flexible movement. The bearing housing is lubricated by high pressure during start-up and stop-up, and the oil film is formed by static pressure. The journal is lifted up to prevent dry friction on the sliding surface, and the starting energy moment is reduced. The bearing lining is provided with a snake-shaped cooling water pipe, which can supply cooling water when necessary to reduce the temperature of the bearing bush. The cooling water pipe is made of red copper which has certain corrosion resistance.
Ball mill power is relatively large, the appropriate choice of hydrostatic sliding bearing. The main bearing bush is lined with babbitt alloy bush, each bush has two high-pressure oil chambers, high-pressure oil has been supplied to the oil chamber before and during the operation of the mill, the high-pressure oil enters the oil chamber through the shunting motor, and the static pressure oil film is compensated automatically to ensure the same oil film thickness To provide a continuous static pressure oil film for mill operation, to ensure that the journal and the bearing Bush are completely out of contact, thus greatly reducing the mill start-up load, and can reduce the impact on the mill transmission part, but also can avoid the abrasion of the bearing Bush, the service life of the bearing Bush is prolonged. The pressure indication of the high pressure oil circuit can be used to reflect the load of the mill indirectly. When the mill stops running, the high pressure oil will float the Journal, and the Journal will stop gradually in the bush, so that the Bush will not be abraded. Each main bearing is equipped with two temperature probe, dynamic monitoring of the bearing Bush temperature, when the temperature is greater than the specified temperature value, it can automatically alarm and stop grinding. In order to compensate for the change of the mill length due to temperature, there is a gap between the hollow journal at the feeding end and the bearing Bush width, which allows the journal to move axially on the bearing Bush. The two ends of the main bearing are sealed in an annular way and filled with grease through the lubricating oil pipe to prevent the leakage of the lubricating oil and the entry of dust.
The end cover of the autogenous mill is made of steel plate and welded into one body; the structure is simple, but the rigidity and strength are low; the liner of the autogenous mill is made of high manganese steel.
The end cover and the hollow shaft can be made into an integral or split type according to the actual situation of the project. No matter the integral or split type structure, the end cover and the hollow shaft are all made of Casting After rough machining, the key parts are detected by ultrasonic, and after finishing, the surface is detected by magnetic particle. The surface of the hollow shaft journal is Polished after machining. The end cover and the cylinder body are all connected by high-strength bolts. Strict process measures to control the machining accuracy of the joint surface stop, to ensure reliable connection and the concentricity of the two end journal after final assembly. According to the actual situation of the project, the cylinder can be made as a whole or divided, with a flanged connection and stop positioning. All welds are penetration welds, and all welds are inspected by ultrasonic nondestructive testing After welding, the whole Shell is returned to the furnace for tempering stress relief treatment, and after heat treatment, the shell surface is shot-peened. The lining plate of the ball mill is usually made of alloy material.
The transmission part comprises a gear and a gear, a gear housing, a gear housing and an accessory thereof. The big gear of the transmission part of the self-grinding machine fits on the hollow shaft of the discharge material, which is smaller in size, but the seal of the gear cover is not good, and the ore slurry easily enters the hollow shaft of the discharge material, causing the hollow shaft to wear.
The big gear of the ball mill fits on the mill shell, the size is bigger, the big gear is divided into half structure, the radial and axial run-out of the big gear are controlled within the national standard, the aging treatment is up to the standard, and the stress and deformation after processing are prevented. The big gear seal adopts the radial seal and the reinforced big gear shield. It is welded and manufactured in the workshop. The geometric size is controlled, the deformation is prevented and the sealing effect is ensured. The small gear transmission device adopts the cast iron base, the bearing base and the bearing cap are processed at the same time to reduce the vibration in operation. Large and small gear lubrication: The use of spray lubrication device timing quantitative forced spray lubrication, automatic control, no manual operation. The gear cover is welded by profile steel and high-quality steel plate. In order to enhance the stiffness of the gear cover, the finite element analysis is carried out, and the supporting structure is added in the weak part according to the analysis results.
The self-mill adopts the self-return device to realize the discharge of the mill. The self-returning device is located in the revolving part of the mill, and the material forms a self-circulation in the revolving part of the mill through the self-returning device, discharging the qualified material from the mill, leading the unqualified material back into the revolving part to participate in the grinding operation.
The ball mill adopts a discharge screen similar to the ball mill, and the function of blocking the internal medium of the overflow ball mill is accomplished inside the rotary part of the ball mill. The discharge screen is only responsible for forcing out a small amount of the medium that overflows into the discharge screen through the internal welding reverse spiral, to achieve forced discharge mill.
The slow drive consists of a brake motor, a coupling, a planetary reducer and a claw-type clutch. The device is connected to a pinion shaft and is used for mill maintenance and replacement of liners. In addition, after the mill is shut down for a long time, the slow-speed transmission device before starting the main motor can eliminate the eccentric load of the steel ball, loosen the consolidation of the steel ball and materials, ensure safe start, avoid overloading of the air clutch, and play a protective role. The slow-speed transmission device can realize the point-to-point reverse in the electronic control design. When connecting the main motor drive, the claw-type Clutch automatically disengages, the maintenance personnel should pay attention to the safety.
The slow drive device of the ball mill is provided with a rack and pinion structure, and the operating handle is moved to the side away from the cylinder body The utility model not only reduces the labor intensity but also ensures the safety of the operators.
The cast steel spider cap has been designed to serve as a feed distribution plate for coarse materials. It is recessed on the 22, 30, 36 and 48-in. crushers. For fine materials, the wobble plate feeder a more effective means of distributing the feed is recommended.
The annealed cast steel top shell and spider are made in one piece. The spider is of the three arm type, equipped with a self-aligning, Scor-Proof plastic ball and socket bearing in crusher sizes 22 to 48-in., and with an hourglass type bearing in sizes above 48-in. The lubricant is sealed in with a garter type oil seal. Bearings can be lubricated from outside the topshell on the 51, 60 and 84-in. crushers through oil holes in spider caps of the four smaller sizes.
The mainshaft is of high grade forged steel, annealed for stress relief. It is tapered to gauge for head center fit. The bottom of the shaft is fitted with a polished bronze step bearing. The journal for the spider bearing is formed by a sleeve shrunk on the shaft on the 51, 60 and 84-in. crushers. Short, heavy mainshaft design results in long life.
The step bearing consists of a bronze mainshaft step, a bronze piston wearing plate, and an alloy steel washer between the two. The washer is drilled for oil cooling and lubrication. Both the mainshaft step and the piston wearing plate are made of high lead bronze, selected to give the best bearing surface. The washer and plate are pinned in place, and the bearing surfaces are grooved to permit distribution of the lubricating oil.
The Mantalloy head mantle of this cone crusher is a replaceable wearing surface. It is made of alloyed manganese steel, and is held in place with a self-tightening head nut. On the 51-in. Hydrocone crushers and larger, the bottom portion of the mantle is ground to gauge to fit the head center, and the top portion is zinced. For crushers smaller than 51-in., the entire inner surface of the mantle is ground to gauge and no zincing is required.
The Mantalloy concave ring, or the stationary crushing surface, is available in three standard types, coarse, intermediate and fine. Helices, cast into the bottom of the concave ring, engage similar helices on the top of a cast steel concave support ring. The support ring is held by a key to the top shell to facilitate assembly, after which it is supported on the bottom shell. The helical surfaces make the concave ring self-tightening; no zincing is required.
The dust seal is a plastic ring suspended in a housing from the head center and encircling the dust collar. It is designed to accommodate the vertical adjustment and the gyrating and rotating motion of the head. All wearing parts are replaceable. The crusher is fitted with a connection for introducing low pressure air inside the seal for additional dust protection.
The eccentric is made of high carbon cast steel and fitted with a bronze inner wearing sleeve. The eccentric turns in a bronze bottom shell bushing. Both sleeve and bushing are replaceable. The eccentric throw can be changed in the field by installing a different sleeve.
The alloy steel pinion is mounted on a turned shaft. The cast steel pinionshaft housing is bolted to the machined opening in the bottom shell. It is equipped with anti-friction bearings sealed inside and out, and has separate pool lubrication in all sizes except the 36 and 48-inch machines. The 36 and 48-inch Hydrocone crushers have sleeve type counter-shaft bearings which are lubricated by the external oiling system.
The annealed cast steel bottom shell is of the three arm, open discharge type, bored to gauge for the top shell and eccentric bushing. It is bored and faced for the bottom plate, pinionshaft bearing and dust collar.
The external oil conditioning system furnished with Hydrocone crushers consists of a large oil storage tank on which are mounted a condenser type cooler, pressure type filter, motor, and a pump which pumps the lubricant to the crusher automatically. These units both cool and filter the oil. The accumulator and tank for the Automatic Reset are mounted separately from the oil storage tank.
All oil conditioning systems are equipped with oil flow and temperature safety switches which are adjusted to open the motor circuit and stop the crusher if the temperature becomes too high or if there is not a sufficient flow of oil. Flexible hose connects the lubricating unit to the crushers, greatly reducing the number of pipe fittings required and simplifying the installation.
Oil for the tank is pumped through the filter and cooler to the step bearing and up the inner eccentric bearing. It flows down the outer eccentric bearing, lubricates the gear and pinion, then returns to the tank. Tank capacities vary from 30 gallons for the 22-in. Hydrocone crusher to 240 gallons for the 84-in. machine.
23. Feed Plate 24. Screw 25. Torch Ring 26. Locking Bolt 27. Dust Shell 28. Clamp Ring 29. Adjustment Ring 30. Mainshaft Pin 31. Pin 32. Socket Liner 33. Socket 34. Eccentric 35. Eccentric Bushing 36. Counterweight 37. Counterweight Guard 38. Gear 39. Thrust Bearing 40. Countershaft Box 41. Countershaft Box Guard 42. Oil Finger Cover 43. Oil Finger 44. Countershaft Bushing 45. Countershaft 46. Pinion
CRUSHING CHAMBER may be any one of three standard types (Fine, Intermediate and Coarse) designed to assure a cubical, well-graded product. Shape of mantle and concave ring, and the range of adjustment available, results in maximum life and minimum scrap when replacing parts. Special crushing chambers also available.
BEVEL PINION AND GEAR are of the spiral design in the larger sizes provide greater tooth contact and smooth, trouble-free operation under most severe conditions. Bevel spur and pinion gears are used on smaller size Hydrocone crushers.
INNER CRUSHING CONE or mantle is one-piece Mantalloy casting held in place by a self-locking head nut. Complete contact of the ground inner surface with steel head center eliminates need for zincing in all but the larger sizes.
OUTER CRUSHING RING or concave ring is one-piece Mantalloy casting. Necessity of zincing or clamping concave ring in place is eliminated by ground-to-fit finish on outer surface and the use of an effective self-locking device.
3-PIECE STEP BEARING accommodates gyrating motion of main shaft and transmits crushing pressure to hydraulic piston. Designed to withstand bearing pressures much greater than those encountered in actual service.
While it is one of the major parts in the machine, there are few essential differences between the adjustment ring in the 10 ft. crusher and in the smaller machines, except as to size. Material of the ring which weighs 70,000 pounds is cast steel. Rigidity of the adjustment ring cross-section is essential. In this case, increased section thickness, with ordinary carbon steels, results in a reduction in deflection.
This part, which is screwed into the adjustment ring, is the means of setting of the machine. Adjustment is performed by rotating the bowl relative to the adjustment ring. In the 10 ft. machine provision has been made to adjust the setting during crushing. This increases the availability of the crusher substantially. Past practice had been to stop feed to the crusher during adjustment.
During crushing the position of the bowl and adjustment ring is maintained on the slant flank of the threads by means of the crushing force. The slant flank helps in centering the two elements. The clamp ring acts somewhat like a locking device to take up clearances. Ideally, the clamping cylinders do not have to have any greater capacity than is necessary to overcome the weight of the bowl. Practically, the clamp ring capacity is many times higher to withstand tramp passage.
To adjust the setting of the machine, hydraulic rams are used to rotate or counter-rotate the bowl in the adjustment ring. The seal between the adjustment cap and hopper is a simple, continuous, tightly fitting flap which allows free, relative rotation but prevents intrusion of dust into the thread area. The lower end of the thread connection between bowl and adjustment ring is also sealed. The hopper assembly, which is actually a part of the bowl assembly, including the hopper, hopper liner and cap closure, comprises the section in which the feed is introduced. It includes a dead bed, reducing wear and shock from the fall of the feed from the feeder above.
The adjustment rams are pressurized hydraulically and provide a setting adjustment. For normal adjustment of setting due to wear, installation and removal of the bowl is made through a swivel sheave and a cable turn applied around the adjustment cap. The bowl is then rotated by use of the maintenance crane.
The crushing head, similar in section to that of the 7 ft. machine, had three-dimensional photoelastic studies made using the technique of freezing stresses into a loaded plastic model, sectioning the model and examining the slices under polarized light. As a result of these techniques, stresses have been reduced. The core of the head consists of six massive ribs to support the crushing forces on the surface of the head. The head is cast steel.
The main shaft is of turbine rotor steel of high quality and refinement, the chemistry of which is low carbon to reduce the possibility of heat checking. It includes chrome nickel additions for deep hardening, notch toughness and resistance to fatigue. The shaft extension is provided to reduce the relative strain between the head and shaft and thereby reduce fretting in the fit, which has a heavy press. The shaft diameter is 50 percent greater than the 7 ft. crusher shaft. As a result, the shaft operates at lower values of bending stress and deflection. Reduced deflection produces distinct benefits in bearing behavior because of uniformity of oil film under load. Reduced stresses assure longer life and resistance to overloads.
The head-shaft assembly is supported by the socket and socket liner which is, in essence, a spherical thrust bearing. The function is to carry the vertical component of the crushing force while allowing the head to oscillate around the theoretical center of rotation.
The socket of carbon steel is of dowelled design. The forces between the head and the socket are normal to the spherical surface of the head and pass through the theoretical center. The line of action of these forces is such that practically pure compression is applied to the socket and liner, reducing deflection and stress to a minimum and promoting good bearing performance.
The force distribution throughout the crusher is based on a vector diagram of the cavity forces during crushing and the reactions at various associated loading points in the crusher. The vector diagram establishes their relative magnitude, direction and points of application. The actual magnitude of these forces is established by the crushing force necessary to lift the adjustment ring off the frame seat. This condition represents the maximum allowable force for normal crushing.
A baffle ring attached to the head is sub-merged around its entire periphery in a water trough resting on the socket. Dust tends to settle into the trough and must be continuously removed to prevent caking. For this reason, water is continuously fed through specially designed nozzles which scour the trough. Overflow water is carried off by internal piping and passages. The seal chamber is vented to atmosphere to prevent siphoning which may cause oil contamination of the water or vice versa.
The gears are straight tooth bevel gears and are designed to AGMA standards using a computerized program which, upon input of the basic information, such as DP, diameters, gear ratio, material properties, tooth type, provides a complete printout of the rated power on the basis of tooth strength and surface durability of the gear. The factor of safety on the gear is in excess of three on the strength basis and in excess of two on the durability basis.
A Cone Crusher is a compression type of machine that reduces material by squeezing or compressing the feed material between a moving piece of steel and a stationary piece of steel. Final sizing and reduction is determined by the closed side setting or the gap between the two crushing members at the lowest point. As the wedge or eccentric rotates to cause the compression within the chamber, the material gets smaller as it moves down through the wear liner as the opening in the cavity gets tighter. The crushed material is discharged at the bottom of the machine after they pass through the cavity.
A Cone Crusher will deliver a 4:1 to 6:1 reduction ratio. As we set the closed side setting tighter to create a finer output, we also reduce the volume or throughput capacity of the machine. Generally speaking, multiplying the closed side setting by two is a good guide to the top size of the gradation exiting the machine.
The technology that makes a MSP Cone Crusher outperform competitive cones on the market is the combination of all of the factors of performance i.e. balanced eccentric, higher speeds, fulcrum point position, and stroke. By using sound engineering with years of field testing a truly tried and tested new Cone Crusher has emerged.
A balanced eccentric coupled with a fulcrum point ideally placed over the crushing chamber yields highly effective compression crushing. This allows higher eccentric speeds to maximize performance without disruptive forces. The eccentric stroke is designed to work with the eccentric speed and fulcrum position to produce higher yields and minimize recirculating loads. The torque and resultant crushing forces are as effective as virtually any Cone Crusher on the market.
Spiral bevel gears provide the turning force to the eccentric. The spiral gear is mounted on a sturdy countershaft of the Cone Crusher, which rides in bronze bushings. The gears are precision cut for quiet operation. Misalignment problems are eliminated.
The MSP Cone Crusher features one of the largest volume displacements by a crusher head. When there is a large volume of material displaced this way, it means that more material is crushed in each cycle, more material can be fed to fill the larger void left when the crushing head recedes, and more material flows through the crusher due to the larger throughput and gyrating cycles allowing material to drop further. The benefits of high efficiency, greater crushing force and high capacity coupled with the durability the market expects are the reasons why this design is the best way to increase your productivity and profitability.
Sleeve bearings make removal and installation of the MSP Cone Crusher head and main shaft simple. The tapered main shaft fits into a large opening at the upper end of the tapered eccentric bushing. The shaft does not require precise alignment. It can be inserted from a vertical position and will self-align.
With the MSP Cone Crushers automatic hydraulic overload relief system, the crusher immediately opens in the event of an overload. This action reduces the crushing pressure, allowing the obstruction to pass through the chamber. After the chamber has been cleared, the hydraulic control system automatically returns the crusher to its original setting. Shock loads on the crusher are reduced for longer component life.
MSP Cone Crushers are built to make your operations run more smoothly and easily. Its simple and easy to read control panel provides you with the necessary information to properly run your crusher. For example, the MSP Cone Crusher shows you the exact cone setting to allow the operator to stay on top of a critical set point.
To enhance your Cone Crusher's life and maintain optimal crushing capacities, an automatic liner change reminder is included for your convenience. When the new mantle and liners are installed, the automated reminder is reset. As the crusher operates, the system will track production capacities and calculate the liner wear rate. When the cone liners reach the maximum wear point, it sends a flashing reminder to 'change cone' on the cone setting meter. After the wear parts are changed, simply reset the automated reminder system and continue efficient, reliable crushing.
The MSP Cone Crushers are built heavier than most competitive Cone Crushers. The extra weight means lower stress on the machine, which results in longer operational life. There is no question that the proper use of mass makes for more durable crushers. Additionally, a broad array of manganese liners is offered for each size MSP Cone. A unique and patented feature allows the Liners to fit without the use of any backing material. Improved Chamber matching with crusher feeds virtually eliminates any trial and error.
All these factors combine to give producers more effective compression crushing. This reduces liner wear, which reduces wear cost and allows higher yields, resulting in decreased overall cost per ton of finished product.
In the Symons principle, which is utilized by the MSP Cone Crusher, each cycle is timed so that the feed material and the upward thrust of the crushing head meet at the moment of maximum impact. The optimum speed of gyration and the large eccentric throw produce two important results: 1) the rapidly closing head catches the falling feed material and delivers the extremely high crushing force and 2) on the other side of the chamber the rapidly receding head allows material to fall freely to the next point of impact or exit the chamber. The combination of superior crushing force and free flow of material in the MSP Cone Crusher results in production levels that are unsurpassed and means lower power consumption per ton.
Ten years of testing went into the final combination of speed, stroke, and head angle to deliver the most efficient use of power. Greater efficiency delivers lower power consumption, reduced cost per ton, less maintenance and higher profits.
The power input imparted by the driven eccentric results in a bearing force in opposition to the crushing force at a point on the lower portion of the main shaft. The bearing force as it is transmitted to the main shaft provides the required moment to crush the rock. The distance between the bearing force and the fulcrum point is called the force arm. The longer the force arm, the greater the momentum, which produces a greater crushing force.
Crushing loads are distributed over a large spherical bearing. The socket liner keeps full contact with the crushing head ball and carries all of the vertical component and part of the horizontal. The long force arm, represented by the main shaft, reduces the load transmitted through the eccentric bushing.
Capacities and product gradations produced by Cone Crushers are affected by the method of feeding, characteristics of the material fed, speed of the machine, power applied, and other factors. Hardness, compressive strength, mineral content, grain structure, plasticity, size and shape of feed particles, moisture content, and other characteristics of the material also affect production capacities and gradations. Gradations and capacities are most often based on a typical, well-graded choke feed to the crusher. Well-graded feed is considered to be 90% to 100% passing the closed side feed opening, 40% to 60% passing the midpoint of the crushing chamber on the closed side (average of the closed side feed opening and closed side setting), and 0 to 10% passing the closed side setting. Choke feed is considered to be material located 360 degrees around the crushing head and approximately 6 above the mantle nut. Maximum feed size is the average of the open side feed opening and closed side feed opening.
Minimum closed side setting may vary depending on crushing conditions, the compressive strength of the material being crushed, and stage of reduction. The actual minimum closed side setting is that setting just before the bowl assembly lifts minutely against the factory recommended pressurized hydraulicrelief system.
Overall, industry acceptance of the Symons principle and performance, the McLanahan Cone Crusher works to deliver lower recirculating loads at higher tonnage rates with lower maintenance costs by combining:
A general rule of thumb for applying Cone Crushers is the reduction ratio. A crusher with coarse style liners would typically have a 6:1 reduction ratio. Thus, with a 34 closed side setting, the maximum feed would be 6 x 34 or 4.5 inches. Reduction ratios of 8:1 may be possible in certain coarse crushing applications. Fine liner configurations typically have reduction ratios of 4:1 to 6:1.
The difference between the volume displaced by the crushing head when it is fully closed and fully open is called the displacement volume. A large displacement volume results in greater capacity because:
In order to maintain the maximum levels of capacity, gradation, and cubical product, a Cone Crusher must be choke-fed at all times. The best way to keep a choke-feed to the ConeCrusher is with a surge bin (or hopper) and feeder that are located prior to the crusher. Choke-feeding is almost impossible to achieve without a hopper and feeder.
There are a number of different criteria to consider when selecting the right chambers for your crushing needs. However, the one that must always be considered isthat you have a well-graded feed to the chamber. A well-graded feed is generally thought to be 90 to 100% passing the closed-side feed opening, 40 to 60% passing the midpoint, and 0 to 10% passing the closed-side setting.
One thing you should never do is place a new concave liner in a crusher with a worn mantleor place a new mantle in a crusher with a concave liner. Why? If you have properly selected the replacement component, you will change the complete profile of the Cone Crusher by mating new and worn components. The receiving opening will tend to close down, restricting the feed from entering the chamber and causing a reduction in tons per hour.
If the liner is wearing evenly throughout the chamber, you should consider changing out the manganese when it has worn down to about 1" (2.5 cm) thick at the bottom. At about 3/4" to 5/8" (1.9 to 1.6 cm) thick, the manganese will crack, causing the backing material to begin to disintegrate. This, in turn, will cause the liners to break loose. If this should happen, continued operation could destroy the seat on the support bowl or the head of the Cone Crusher.
McLanahan Symons Principle (MSP) Cone Crushers utilize a combination of improved factors of performance, which are enhanced by the Symons Principle of crushing, as well as the latest hydraulic features and electrical features that create a modern, efficient, reliable and durable Cone Crusher that ultimately leads to a faster ROI. MSP Cone Crushers are designed to make your operation run more smoothly and easily, as well as ensuring lower operating costs and minimal downtime so that MSP Cone Crushers are more frequently fully operational and processing optimal amounts of material.
Efficiency can be defined by the ratio of the work done by a machine to the energy supplied to it. To apply what this means to your crusher, in your reduction process you are producing exactly the sizes your market is demanding. In the past, quarries produced a range of single-size aggregate products up to 40 mm in size. However, the trend for highly specified aggregate has meant that products have become increasingly finer. Currently, many quarries do not produce significant quantities of aggregate coarser than 20 mm; it is not unusual for material coarser than 10 mm to be stockpiled for further crushing.
When it comes to cone crusher eccentric bushing, MGS Casting had supplied all kinds of eccentric bushings for many years. Our bushings are made by C93800 material. Based on our customers feedback, our cone crusher eccentric bushing working life can match the original parts. In some times, our bushing can get more working life. No matter which brand cone crusher eccentric bushings you need, contact us right now.
Casting sections and surfaces critical for strength and finish shall be free of shrinkage, cracks, porosity, blowholes, hot tears which will be detrimental to use of the finished casting. Runners, risers, fins and other cast-on pieces shall be removed and dressed down to blend with the normal profile of the casting surfaces.
Total defects in a casting shall not exceed one percent (1%) of the area of the complete casting surface area. Total defects within any 144 sq. in. (929 sq. cm.) casting surface area shall not exceed two percent (2%) of that area.
Pin Holes (Porosity) Pin holes less than .063 in. (1.6 mm) diameter do not have to be repaired, unless the area of the perimeter enclosing all pin holes in a surface exceeds one percent (1%) of the total area of that surface, or the defective area will not successfully pass a pressure test, if pressure testing is a requirement. Castings not meeting these requirements shall be subject to the Repair provisions.
Blow Holes Castings having blow holes with diameters greater than .38 in. (9.6 mm) shall be rejected and be subject to the Repair provisions in Section 8.0 above.The accumulated area of all blowholes on a single (rough or machined) surface of the casting shall not exceed 0.8 percent (0.8%) of that surface area. The maximum number of blowholes permitted within any 144 sq. in. (929 sq. cm) the surface area shall not exceed 20.
Cracks Cracks on any bearing surfaces or cracks on any surface which will contribute to strength reduction in any section of the casting shall be rejected. Cracks which appear on non-critical surfaces and which are not detrimental to the strength of the casting shall be repaired by welding.
All brand names, model names or marks are owned by their respective manufacturers. MGS Casting has no affiliation with the OEM. These terms are used for identification purposes only and are not intended to indicate affiliation with or approval by the OEM. All parts are manufactured by, for and warranted by MGS Casting and are not manufactured by, purchased from or warranted by the OEM.
The Spider bushing has an hour glass figure and as such it has a very tight clearance. Once the spider bushing no longer supports the main shaft, the bottom of the main shaft exerts a large amount of force on inner eccentric bushing.
Figure 3 below shows the logic behind the step bushing and the inner eccentric bushing. Imaging holding the bottom of the pencil securely and exerting a force as per the red arrows. This would cause large stress to be exerted at the bottom of the pencil. This is the same logic that applies when the spider bushing is worn.
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