Compound Cone Crusher

Frame Body: A heavy-duty cast steel (ZG270-500) structure that supports all internal components. It has a cylindrical or conical shape with a top flange for mounting the adjustment ring and a bottom base for fixing to the foundation. The frame thickness ranges from 50–150 mm, depending on the crusher size.

Upper Frame: Houses the fixed cone (concave) and adjustment mechanism, with radial ribs (thickness 30–80 mm) to enhance rigidity against crushing forces.

Lower Frame: Contains the eccentric shaft sleeve, main shaft bearing, and transmission components. It features oil passages for lubrication and cooling.

Movable Cone: A conical component with a manganese steel (ZGMn13) or high-chromium cast iron (Cr20) liner (thickness 30–80 mm) attached via zinc alloy casting. The cone body is forged from 42CrMo alloy steel, with a spherical base that fits into the main shaft’s spherical bearing.

Fixed Cone (Concave): A multi-section annular liner (2–4 segments) made of wear-resistant materials, mounted on the upper frame. Each segment corresponds to a crushing stage (coarse to fine), with varying cavity profiles (angle, depth) to control particle size.

Main Shaft: A forged alloy steel (40CrNiMoA) shaft that connects the movable cone to the eccentric shaft sleeve. It has a tapered lower end (1:10 taper) for fitting into the eccentric sleeve and a spherical top for supporting the movable cone.

Eccentric Shaft Sleeve: A cast steel (ZG35CrMo) sleeve with an offset bore (eccentricity 5–20 mm) that drives the main shaft’s oscillating motion. It is mounted on bronze or spherical roller bearings and rotated by a bevel gear set.

Bevel Gears: A pair of high-strength steel (20CrMnTi) gears (small and large) that transmit power from the motor to the eccentric sleeve. The large gear is bolted to the eccentric sleeve, while the small gear is mounted on the input shaft.

Motor and Pulley: A variable-speed motor (110–500 kW) connected to the input shaft via a V-belt and pulley system, allowing speed adjustment (500–1500 rpm) based on material hardness.

Hydraulic Adjustment System: Includes hydraulic cylinders (4–8) mounted on the upper frame to adjust the fixed cone’s height, controlling the discharge port size (5–50 mm). It features position sensors for precise adjustment.

Safety Device: A combination of hydraulic overload protection and spring buffers. When uncrushable materials enter the cavity, hydraulic pressure rises, triggering a relief valve to lift the fixed cone, expel the material, and reset automatically.

Lubrication System: An independent thin oil lubrication system with pumps, coolers, and filters that circulates oil (ISO VG 46) to bearings and gears, maintaining temperatures below 60°C.

Labyrinth Seal: A multi-stage seal between the movable cone and upper frame that prevents dust ingress.

Air Purge System: Compressed air (0.3–0.5 MPa) is injected into the seal area to further block dust, working in conjunction with a water spray system for high-dust environments.

Pattern Making: A full-scale wooden or metal pattern is created, including ribs, flanges, and oil passages. Shrinkage allowances (1.2–1.5%) are added.

Molding: Resin-bonded sand molds are used, with cores for internal cavities. The mold is coated with a refractory wash to improve surface finish.

Melting and Pouring: Steel is melted in an induction furnace at 1520–1560°C, then poured into the mold at 1480–1520°C under controlled pressure to avoid porosity.

Heat Treatment: Normalization at 880–920°C (air-cooled) to refine grain structure, followed by tempering at 550–600°C to reduce brittleness.

Pattern Making: Precision foam patterns with eccentric bore details are used to ensure dimensional accuracy.

Molding: Shell molding with 酚醛树脂 binder for complex geometries, ensuring tight tolerances on the eccentric bore (±0.05 mm).

Pouring and Heat Treatment: Molten steel is poured at 1500–1540°C. After casting, the sleeve undergoes quenching (850°C, oil-cooled) and tempering (580°C) to achieve hardness HB 220–260.

Billet Heating: Steel billets are heated to 1150–1200°C in a gas furnace.

Open-Die Forging: The billet is upset and forged into a conical shape, with the spherical base formed in multiple passes to align grain flow.

Heat Treatment: Quenching (840°C, water-cooled) and tempering (560°C) to achieve tensile strength ≥900 MPa and hardness HRC 28–32.

Rough Machining: CNC milling to shape the flange surfaces, with flatness tolerance (≤0.1 mm/m). Boring machines create bearing seats with cylindrical tolerance IT7.

Precision Machining: Grinding of flange mating surfaces to Ra1.6 μm. Drilling and tapping of bolt holes (M20–M48) with thread class 6H.

Turning: CNC lathes machine the outer diameter and eccentric bore, leaving 0.5–1 mm grinding allowance. The eccentricity is verified with a coordinate measuring machine (CMM).

Grinding: The outer diameter and bore are ground to IT6 tolerance, with surface roughness Ra0.8 μm. The gear mounting face is ground to perpendicularity (≤0.02 mm/100 mm).

Milling: CNC machining centers shape the conical surface and spherical base, with the cone angle tolerance (±0.05°).

Liner Mounting Surface: Machined to flatness (≤0.1 mm/m) to ensure proper bonding with the manganese steel liner.

Material Testing:

Spectrometric analysis verifies chemical composition (e.g., ZG270-500: C 0.24–0.32%, Mn 1.2–1.6%).

Tensile testing ensures mechanical properties (e.g., 42CrMo: yield strength ≥785 MPa).

Dimensional Inspection:

CMM checks critical dimensions (e.g., eccentric sleeve bore eccentricity, frame flange flatness).

Laser scanning verifies the movable cone’s conical profile.

Non-Destructive Testing (NDT):

Ultrasonic testing (UT) detects internal defects in cast components (e.g., frame, eccentric sleeve) with defects >φ3 mm rejected.

Magnetic particle testing (MPT) inspects forged parts (e.g., main shaft) for surface cracks.

Performance Testing:

Dynamic Balancing: Eccentric sleeve and pulley assemblies are balanced to G2.5 grade (vibration ≤2.5 mm/s).

Lubrication System Test: Flow rate and pressure (0.2–0.4 MPa) are verified, with no leaks allowed.

Crushing Test: A 24-hour continuous run with standard aggregate (e.g., granite) checks production capacity, particle size distribution, and component wear.

Safety Validation:

Overload testing with iron blocks (50–100 kg) confirms the safety device triggers within 2 seconds, with no damage to components.