The cone crusher bowl liner, also known as the fixed cone liner or concave liner, is a wear-resistant component mounted on the inner surface of the upper frame or bowl, forming the stationary part of the crushing chamber. Its main functions include material crushing (cooperating with the moving cone liner to reduce materials), wear protection (shielding the upper frame), material guidance (ensuring uniform material distribution via its inner profile), and product size control (influencing particle size distribution through its inner profile). It requires exceptional wear resistance, impact toughness, and structural integrity, with a service life of 500–2000 hours depending on material hardness.
Structurally, it is a conical or frustoconical component consisting of the liner body (high-chromium cast iron like Cr20–Cr26 or martensitic steel), inner wear profile (with parallel sections, stepped/grooved surfaces, and a 15°–30° taper angle), mounting features (dovetail grooves, bolt holes, locating pins), reinforcement ribs, and a top flange.
The casting process of the bowl liner involves material selection (high-chromium cast iron Cr20Mo3), pattern making (with shrinkage allowances), molding (resin-bonded sand mold), melting and pouring (controlled temperature and flow rate), cooling and shakeout, and heat treatment (solution annealing and austempering). Its machining and manufacturing process includes rough machining, mounting feature machining, inner profile machining, and surface treatment.
Quality control processes cover material testing (chemical composition and metallographic analysis), mechanical property testing (hardness and impact testing), dimensional accuracy checks (using CMM and laser scanner), non-destructive testing (ultrasonic and magnetic particle testing), and wear performance testing. These processes ensure the bowl liner has the required wear resistance, precision, and durabil
Detailed Introduction to the Cone Crusher Bowl Liner Component
1. Function and Role of the Bowl Liner
The cone crusher bowl liner (also called the fixed cone liner or concave liner) is a wear-resistant component mounted on the inner surface of the upper frame or bowl, forming the stationary part of the crushing chamber. Its primary functions include:
Material Crushing: Working in conjunction with the moving cone liner (mantle) to apply compressive and shear forces to materials (ores, rocks), reducing them to the desired particle size.
Wear Protection: Shielding the upper frame from direct contact with abrasive materials, extending the service life of the frame and reducing maintenance costs.
Material Guidance: Guiding materials through the crushing chamber via its tapered or stepped inner surface, ensuring uniform distribution and efficient crushing.
Product Size Control: The liner’s inner profile (e.g., parallel, convex, or concave sections) directly influences the crushing gap and particle size distribution of the final product.
Given its exposure to high-impact, high-abrasion conditions, the bowl liner must 具备 exceptional wear resistance, impact toughness, and structural integrity, typically lasting 500–2000 hours depending on material hardness.
2. Composition and Structure of the Bowl Liner
The bowl liner is a conical or frustoconical component with a complex inner profile, consisting of the following key parts and structural features:
Liner Body: The main structure, made of high-chromium cast iron (e.g., Cr20–Cr26) or martensitic steel (e.g., 12Cr13), with a thickness ranging from 50–150 mm. Its outer surface is machined to fit the upper frame, while the inner surface features a wear-resistant profile.
Inner Wear Profile: Designed with specific geometries to optimize crushing efficiency:
Parallel Sections: For producing uniform fine particles by maintaining a consistent crushing gap.
Stepped or Grooved Surfaces: Enhancing material gripping and reducing slippage, suitable for coarse crushing.
Taper Angle: Typically 15°–30° relative to the vertical axis, determining the material flow rate and crushing force distribution.
Mounting Features:
Dovetail Grooves: Longitudinal grooves on the outer surface that mate with corresponding protrusions on the upper frame, securing the liner against rotational forces.
Bolt Holes: Circumferential holes near the top/bottom edges for bolts that fasten the liner to the frame, preventing axial displacement.
Locating Pins: Small protrusions or holes that align the liner with the frame, ensuring proper positioning of the inner profile.
Reinforcement Ribs: External radial ribs (10–30 mm thick) that strengthen the liner body, reducing deformation under impact loads.
Top Flange: A radial edge at the upper end that overlaps with the feed hopper, preventing material leakage between the liner and frame.
3. Casting Process for the Bowl Liner
High-chromium cast iron, the primary material for bowl liners, is manufactured via sand casting to achieve complex wear profiles:
Material Selection:
High-chromium cast iron (Cr20Mo3) is preferred for its excellent wear resistance (hardness ≥HRC 60) and impact toughness (≥15 J/cm²). The chemical composition is controlled to C 2.5–3.5%, Cr 20–26%, Mo 0.5–1.0% to form hard chromium carbides (M7C3) in the matrix.
Pattern Making:
A full-scale pattern is created using wood, foam, or 3D-printed resin, replicating the liner’s inner profile, outer surface, mounting features, and ribs. Shrinkage allowances (1.5–2.5%) are added to account for cooling contraction of cast iron.
Molding:
A resin-bonded sand mold is prepared, with the pattern positioned to form the outer surface of the liner. A sand core (coated with refractory wash) creates the inner wear profile, ensuring dimensional accuracy of the taper angle and grooves.
Melting and Pouring:
The cast iron is melted in an induction furnace at 1450–1500°C, with strict control of carbon equivalent (CE = C + 0.3(Si + P) ≤4.2%) to avoid shrinkage defects.
Pouring is performed at 1380–1420°C using a ladle, with a slow, steady flow rate to fill the mold cavity without turbulence, which can cause porosity in the casting.
Cooling and Shakeout:
The mold is cooled for 24–48 hours to reduce thermal stress, then the casting is removed via vibration. Sand residues are cleaned using shot blasting (G25 steel grit), achieving a surface roughness of Ra50–100 μm.
Heat Treatment:
Solution Annealing: The casting is heated to 950–1050°C, held for 2–4 hours, then air-cooled to dissolve carbides and homogenize the structure.
Austempering: Quenching in oil at 250–350°C, followed by tempering at 200–250°C to transform the matrix into martensite, achieving hardness HRC 60–65 while maintaining toughness.
4. Machining and Manufacturing Process
Rough Machining:
The cast liner is mounted on a CNC vertical lathe to machine the outer surface, top flange, and bolt hole locations, leaving 1–2 mm finishing allowance. Key dimensions (e.g., outer diameter, taper angle) are controlled to ±0.5 mm.
Mounting Feature Machining:
Dovetail grooves are milled into the outer surface using a CNC milling machine, with depth tolerance (±0.1 mm) and uniform spacing to ensure a tight fit with the frame’s protrusions.
Bolt holes are drilled and tapped to class 6H tolerance, with positional accuracy (±0.2 mm) relative to the liner’s axis, preventing bolt stress concentration.
Inner Profile Machining:
The inner wear surface is rough-turned to the approximate profile, then finish-ground using a CNC grinder with a contouring tool. The surface roughness is controlled to Ra3.2 μm to optimize material flow and reduce wear.
Taper angle is verified using a laser scanner, ensuring it matches the design (tolerance ±0.1°) to maintain the correct crushing gap with the moving cone.
Surface Treatment:
The outer surface (mating with the frame) is coated with anti-rust paint to prevent corrosion during storage.
The inner wear surface may be subjected to shot peening (using steel shots of 0.3–0.8 mm) to induce compressive stress, improving fatigue resistance.
5. Quality Control Processes
Material Testing:
Chemical composition analysis (spectrometry) confirms the cast iron meets standards (e.g., Cr20Mo3: Cr 20–23%, C 2.8–3.2%).
Metallographic analysis checks the distribution of chromium carbides (volume fraction ≥30%) and matrix structure (martensite with ≤5% pearlite).
Mechanical Property Testing:
Hardness testing (Rockwell) ensures the inner surface has hardness ≥HRC 60; core hardness is checked to confirm uniform heat treatment (≤HRC 55 for toughness).
Impact testing (Charpy V-notch) measures toughness at room temperature, requiring ≥12 J/cm² to resist fracture under impact.
Dimensional Accuracy Checks:
A coordinate measuring machine (CMM) inspects key dimensions: outer diameter (±0.2 mm), inner profile (±0.1 mm deviation from CAD model), and taper angle (±0.1°).
A template gauge verifies the inner wear profile matches the design, ensuring proper crushing gap with the moving cone.
Non-Destructive Testing (NDT):
Ultrasonic testing (UT) detects internal defects (e.g., shrinkage pores, cracks) in the liner body, with a size limit of φ3 mm.
Magnetic particle testing (MPT) checks for surface cracks in dovetail grooves and bolt holes, with any crack >0.2 mm in length resulting in rejection.
Wear Performance Testing:
Accelerated wear testing using a dry sand/rubber wheel apparatus (ASTM G65) measures weight loss, with Cr20 liners requiring ≤0.5 g/1000 cycles.
A bench test mounts the liner with a moving cone, crushing 10 tons of standard ore; post-test inspection shows uniform wear with no chipping or peeling.
Through these manufacturing and quality control processes, the bowl liner achieves the wear resistance, precision, and durability required to ensure efficient, long-term crushing performance in cone crushers, suitable for mining, quarrying, and aggregate processing applications
