Looseness, fracture, abrasion, etc. are the main reasons for failure of hammer of impact crusher, which greatly shortens the service life of the hammer and increases the consumption of parts.
In order to save production costs and improve efficiency, it is necessary for users to understand the reasons for excessive consumption of the hammer, so as to take corresponding measures in time.
As we all know, excessive consumption of hammer of impact crusher is related to the following 6 points:
1. The quality of the bolts (on plate hammer) is poor
Some manufacturers are lack of advanced production processes, and the hammer of their impact still use the bolted fixing method. This fixing method is easy to cause the bolts (fixed on the surface of hammer) subject to the shear force exerted by materials. If coupled with the poor manufacturing of bolts, which will easily cause the hammer to loosen, fall off or break, and shorten the service life.
But large-scale equipment manufacturers generally use pressure plate fixing or wedging fixing method, there is no doubt that the latter is more stable.
2. Inappropriate hammer making materials
The plate hammer of impact crusher is often made by high manganese steel, which is characterized by good toughness, high strength, good manufacturability, and a certain degree of hardness. Under the action of greater impact or stress, the surface layer of high manganese steel will rapidly produce violent, which can greatly improve surface hardness and wear resistance.
In addition, the material of the hammer is mostly high chromium cast iron with higher hardness, but its toughness is lower, and brittle fracture is prone to occur in the occasion of high impact. In order to improve the strength of the hammer and reduce the cost, some manufacturers overlay a layer of high chromium cast iron on the high manganese steel hammer to achieve wear resistance. In order to improve the strength of hammer and reduce the cost, some manufacturers overlay a layer of high chromium cast iron on the high manganese steel hammer to achieve wear resistance.
3. Low manufacturing level of hammer
In the current market, the quality of impact crusher is different. Some manufacturers use shoddy materials in the production process, but users can't see the difference from the appearance.
4. Improper hammer structure
There are many types of hammer structures, wide-thick and narrow-thin working surface, single-head and double-head… Generally, the wide-thick surface structure of impact crusher is more wear-resistant, and single-head only have one wear surface, but the double-head impact crusher has two wear surfaces, and the double head and two sides have four wear surfaces. Under the same material conditions, plate hammer with wear-resistant and many wear surfaces will naturally have a long service life.
5. Improper materials
1) Generally, impact crusher can crush materials whose particle is no more than 350mm, and the crushing strength is not more than 320 MPa, like granite, basalt and limestone.
If the operator doesn’t strictly follow the crushing requirements to feed the material (the material is too hard or the particle size is too large), which will cause the plate hammer to be consumed too quickly.
2) If the crushing stones are too many viscous materials, which may cause a large amount of materials stick to the hammer, causing the hammer to overload.
3) If the impact speed of the material is too large, the crushing ratio of impact crusher will be greater, and the consumption of plate hammer will also increase. Therefore, it is not possible to blindly pursue high capacity; this will make the hammer consumption serious. Users should reduce the line speed as much as possible on the premise of meeting the production volume requirements.
6. Improper use and maintenance
Due to the frequent breakage of hammer, the operators may be too lazy to check the operation of impact crusher because of the heavy workload, which may cause the bolts loose and cannot be tightened in time, causing the hammer is loose or broken, etc. Correct maintenance affects the service life of the equipment to a large extent.
To sum up, if you want to reduce the consumption of hammer and increase its service life, you can start from the above 6 points, strictly control the production process of hammer according to the requirements of operation, and do a good job in equipment maintenance, minimizing the frequency of replacement of hammer, and to save production costs and Improve efficiency.