This paper details the cone crusher torch ring, a vital sealing and protective component situated between key assemblies like the adjustment ring and main frame, or moving cone and fixed cone. Its primary functions include high-temperature sealing (withstanding up to 150°C), preventing contamination, thermal insulation, and vibration absorption, requiring heat resistance, oil resistance, and mechanical strength.
The torch ring has a composite structure, consisting of a metal framework (low-carbon or alloy cast steel) with a U/L-shaped cross-section, a sealing liner (high-temperature rubber, graphite composite, or metal-reinforced felt), retention grooves, flange edges, and optional vent holes.
The metal framework is produced via sand casting: material selection (Q235 or ZG230–450), pattern making with shrinkage allowances, green sand molding, melting and pouring (1450–1480°C), cooling and shakeout, and annealing for stress relief. The machining and manufacturing process involves framework machining, sealing liner preparation, liner bonding with heat-resistant adhesive, finishing, and optional surface treatment.
Quality control includes material testing (chemical composition, tensile strength, hardness), dimensional checks (CMM for accuracy), bond strength testing, seal performance evaluations (pressure and heat cycling), and visual/functional inspections. These ensure the torch ring provides reliable sealing in high-temperature, high-vibration conditions, safeguarding internal components and ensuring efficient crusher operation.
Detailed Introduction to the Cone Crusher Torch Ring Component
1. Function and Role of the Torch Ring
The cone crusher torch ring (also known as the fire ring or seal ring) is a critical sealing and protective component located between the adjustment ring and the main frame, or between the moving cone and the fixed cone assembly. Its primary functions include:
High-Temperature Sealing: Withstanding frictional heat generated during crushing (temperatures up to 150°C) to maintain a tight seal, preventing leakage of lubricating oil or ingress of cooling water.
Contamination Prevention: Blocking dust, ore particles, and other debris from entering the internal lubrication system, reducing wear on bearings and gears.
Thermal Insulation: Separating the high-temperature crushing chamber from the low-temperature lubrication system, protecting sensitive components from heat damage.
Vibration Absorption: Absorbing minor radial and axial vibrations between mating parts, reducing noise and extending the service life of adjacent components.
Given its exposure to high temperatures, abrasion, and chemical corrosion (from ore minerals), the torch ring must 具备 heat resistance (up to 200°C), oil resistance, and mechanical strength.
2. Composition and Structure of the Torch Ring
The torch ring is typically an annular component with a composite structure, combining metal and non-metallic materials. Its key components and structural details include:
Metal Framework: A circular base made of low-carbon steel (Q235 or 10# steel)，providing structural rigidity. It features a U-shaped or L-shaped cross-section to support the sealing material and ensure dimensional stability under heat.
Sealing Liner: A wear-resistant, heat-resistant material bonded or mechanically fixed to the metal framework. Common materials include:
High-Temperature Rubber (EPDM or Viton): Resistant to oils and temperatures up to 200°C，used in moderate-heat applications.
Graphite-Embedded Composite: Enhances heat resistance (up to 300°C) and self-lubrication，suitable for high-friction environments.
Metal-Reinforced Felt: Compressed wool or synthetic fibers impregnated with heat-resistant resin，offering good conformability to uneven surfaces.
Retention Grooves: Circumferential grooves on the metal framework to secure the sealing liner，preventing detachment during vibration.
Flange Edges: Thin, flexible lips on the sealing liner that press against mating surfaces (adjustment ring or main frame) to create a tight seal under preload.
Vent Holes (Optional): Small holes drilled through the metal framework to release trapped air or moisture，preventing pressure buildup that could disrupt the seal.
3. Casting Process for the Metal Framework
The metal framework of the torch ring is often manufactured via sand casting for cost-effectiveness and complex shapes:
Material Selection:
Low-carbon steel (Q235) is preferred for its good castability，weldability，and moderate strength (tensile strength ≥375 MPa). For high-stress applications，alloy cast steel (ZG230–450) is used to improve rigidity.
Pattern Making:
A wooden or foam pattern is crafted to replicate the ring’s outer diameter (typically 300–1200 mm)，inner diameter，and cross-sectional shape (U/L-shaped). Shrinkage allowances (1.2–1.5%) are added to account for cooling contraction.
Molding:
Green sand molds are prepared with a cope and drag，using a sand core to form the inner bore. The mold cavity is coated with a clay-based wash to ensure a smooth surface finish on the casting.
Melting and Pouring:
The steel is melted in a cupola or electric furnace at 1500–1550°C，with chemical composition controlled to C 0.12–0.20%，Mn 0.3–0.6% (for Q235) to avoid brittleness.
Pouring is performed at 1450–1480°C using a ladle，with a steady flow rate to fill the mold cavity without turbulence，reducing porosity.
Cooling and Shakeout:
The casting is cooled in the mold for 12–24 hours to minimize thermal stress，then removed via vibration. Sand residues are cleaned using shot blasting (G40 steel grit).
Heat Treatment:
Annealing at 600–650°C (air-cooled) relieves casting stress，reducing hardness to 130–180 HBW for easier machining.
4. Machining and Manufacturing Process
Framework Machining:
The cast ring is mounted on a CNC lathe to machine the outer diameter，inner diameter，and flange surfaces，leaving a 0.5–1 mm finish allowance. Key dimensions (e.g.，ring width，flange thickness) are controlled to ±0.1 mm.
Retention grooves for the sealing liner are milled using a CNC milling machine，with precise depth (2–5 mm) and width (3–8 mm) to ensure a secure bond.
Sealing Liner Preparation:
For rubber liners: EPDM or Viton sheets are cut to size using die cutting，with a tolerance of ±0.5 mm. The bonding surface is roughened via sandblasting (Ra25–50 μm) to improve adhesion.
For graphite composites: Compressed graphite sheets are cut and shaped using water jet cutting，ensuring uniform thickness (3–10 mm) across the ring.
Liner Bonding:
The metal framework’s bonding surface is cleaned with acetone to remove oil and debris. A heat-resistant adhesive (epoxy-based，with operating temperature up to 200°C) is applied uniformly at a thickness of 0.1–0.2 mm.
The liner is pressed onto the framework using a hydraulic press (pressure: 0.5–1 MPa) and cured in an oven at 80–100°C for 2–4 hours to achieve full bond strength.
Finishing:
The assembled ring is finish-turned to ensure the sealing lips have a smooth surface (Ra1.6–3.2 μm)，promoting effective contact with mating components.
Flange edges are deburred to remove sharp corners，preventing damage to adjacent seals during installation.
Optional Surface Treatment:
The metal framework is coated with zinc plating (5–8 μm) or epoxy paint to resist corrosion in humid environments.
5. Quality Control Processes
Material Testing:
Metal framework: Spectrometric analysis verifies chemical composition (e.g.，Q235: C ≤0.22%，Mn ≤1.4%). Tensile testing confirms strength ≥375 MPa.
Sealing liner: Rubber samples undergo hardness testing (Shore A 60–80 for EPDM) and heat aging tests (70°C for 72 hours，with hardness change ≤±5 Shore A).
Flatness of flange surfaces is measured using a surface plate and feeler gauge，with tolerance ≤0.1 mm/m.
Bond Strength Testing:
Destructive testing of sample rings: A section of the liner is pulled perpendicular to the framework using a tensile tester，requiring minimum bond strength of 3 MPa for rubber liners and 5 MPa for graphite composites.
Seal Performance Testing:
Pressure testing: The ring is installed in a test fixture and subjected to 0.3 MPa air pressure for 30 minutes，with no leakage detected via soap solution application.
Heat cycling: The ring is exposed to 200°C for 1 hour，then cooled to 25°C (repeated 100 cycles)，with post-test inspection showing no liner detachment or cracking.
Visual and Functional Inspection:
The sealing lips are inspected under magnification (10x) to ensure no tears，bubbles，or irregularities.
A trial fit with mating components (adjustment ring，main frame) confirms proper alignment and contact pressure across the entire sealing surface.
Through these processes，the torch ring achieves reliable sealing performance in high-temperature，high-vibration environments，protecting the cone crusher’s internal components and ensuring long-term operational efficiency
