Measuring the value of liner profile gauges

Cone crusher liner profile gauges have gained significant interest among quarrying producers in recent years.

There are three gauges available in the crushing market: the mantle wear profile gauge (Figure 1); the bowl liner profile gauge (Figure 2); and the “A” dimension gauge (Figure 3).

There are many stages of crusher wear liner manufacture that can influence the wear life of the manganese steel crusher liner. The optimum mechanical properties, including wear, are obtained by professional foundry method design, good control of chemistry, controlled foundry melting practice – including furnace charge integrity – optimum grain size (inoculation) and heat treatment. Having all these procedures correct leads to the start for achieving optimum wear life.

{{image2-a:r-w:300}}Before the manufacture process begins, it is critical the casting method design will ensure the entire wear profile will be sound. Many foundries save costs by reducing the number of feeder risers, leading to varying degrees of internal shrinkage (a significant cost saving area for the foundry). Internal shrinkage can be either micro or macro and is often both.

This is a significant factor leading to reduced wear life, and is often not recognised by the end user. The defective area is usually worn away before the liner is removed. The reduced wear life is often incorrectly blamed on the material chemistry.

The initial design of the wear liners is controlled by the original equipment manufacturer (OEM). To allow the OEM to compete in the world market, a “one size fits all” concept is adopted for the wear liners, usually including fine, medium and coarse. This is rarely the best option for the final customer, who has to adapt their crushing plant to suit the large variety of crushed rock products required in the Australian market.

Crushing Equipment, in conjunction with its parent company Foundry Group, maintains a disciplined approach to the manufacture of all supplied crusher wear liners.

With the confidence of a final product leading to consistent liner wear life for each application, the company can focus on customised improvement at individual crushing plants. This is where the use of wear profile gauges begins.

Crusher liner wear profile gauges that have been recently used include the HP300 mantle (Figure 4) and the HP300 concave (Figure 5).

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Cone liner wear gauge

The cone liner wear profile gauge is electronically profile-cut to represent the liner wear profile, and is used for the following:

1. To confirm the start-up crushing profile is correct for current crushing application.
2. To measure the wear rate during the crushing life and determine the optimum change-out time.

The cone liner “A” dimension profile gauge is used for the following:

• To check mantle “A” dimension to ensure the liner is suitable for current crushing application.
• To check the concave and bowl liner “A” dimension to ensure the liner is suitable for the current crushing application.
• To modify the “A” dimension to duplicate existing liners in service.
• To modify the “A” dimensions to use excess closed side settings (CSS) not required for existing crushing requirements.
• To manage liner wear life.

The “A” dimension gauge is an easy method to check the “A” dimension noted on all crushing cone liner drawings.

The “A” dimension starts at the standard size for all liners to meet the crusher design maximum CSS. Should the maximum CSS not be required for the crushing application, the difference between the maximum and that required at the quarry can be added to the “A” dimension (mantle and concave), taking into account the applicable crushing chamber design criteria. This adds to the liner wear life.

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Crusher liner wear gauge

The crusher liner wear profile gauge is used to inspect worn mantle and concave.

These examples are the same for all other cone crushers.

Inspection can be carried out on new liners to confirm the wear face profile, in the crusher during the life cycle to determine the change-out time, and to monitor the wear rate during service and maximise wear life.

The gauge aligns with the liner seating face (main shaft and bowl) and the top of the liner, which usually has minimum wear.

The final stage to achieve optimum wear life is liner design, to ensure the maximum amount of consumable wear material is available for crushing (grams/tonnes crushed).

The maximum thickness of wear material available and the crushing zone length achieve this. Ensuring the liners are matched to give an even wear profile is also a key factor.