錘式破碎機(jī)的設(shè)計(jì)【含4張CAD圖紙+文檔】,含4張CAD圖紙+文檔,破碎,設(shè)計(jì),cad,圖紙,文檔 錘式破碎機(jī)的設(shè)計(jì) 摘要 錘式破碎機(jī)大量應(yīng)用于水泥廠、電廠等各個(gè)部門(mén)，所以，它的設(shè)計(jì)有著廣泛的前景和豐富的可借鑒的經(jīng)驗(yàn)。其設(shè)計(jì)的實(shí)質(zhì)是，在完成總體的設(shè)計(jì)方案以后，就指各個(gè)主要零部件的設(shè)計(jì)、安裝、定位等問(wèn)題，并對(duì)個(gè)別零件進(jìn)行強(qiáng)度校核和試驗(yàn)。并在相關(guān)專題中，對(duì)錘頭的壽命延長(zhǎng)進(jìn)行比較詳細(xì)的分析。在各個(gè)零部件的設(shè)計(jì)中，要包括材料的選擇、尺寸的確定、加工的要求，結(jié)構(gòu)工藝性的滿足，以及與其他零件的配合的要求等。在強(qiáng)度的校核是，要運(yùn)用的相關(guān)公式，進(jìn)行危險(xiǎn)部位的分析、查表、作圖和計(jì)算等。并隨后對(duì)整體進(jìn)行安裝、工作過(guò)程以及工作后的各方面的檢查，同時(shí)兼顧到維修、保險(xiǎn)裝置等方面的問(wèn)題，最后對(duì)兩個(gè)主要工作零件的加工精度、公差選擇進(jìn)行分析，以保證破碎機(jī)最終設(shè)計(jì)的經(jīng)濟(jì)性和可靠性。 關(guān)鍵詞：錘式破碎機(jī)；錘頭；強(qiáng)度；公差 The Design Of the Hammer Crusher Abstract Hammer type breakers are applied to such each department as the cement plant, power plant, etc. in a large amount, so its design has an extensive prospect and experience that can be used for reference. Its design essence is, formerly after total conceptual design, a design which points each main spare part, question of installing and making a reservation etc., and carry on the intensity to check and test to the specific part, and in relevant thematic parts, analysis of comparing question that the life-span of very beginning of the hammer lengthens in detail. In the design of each spare part, should include the choice, sureness, demand processed, structure craft satisfication of the size of the material, and the demand for cooperating with other parts, etc.. When the intensity is checked, should use relevant formulae, carry on the analysis of the dangerous position, need to check form, mapping, calculation, etc.. Then to install , work course , work situation after predict that carries on more overall inspection whole, give consideration to the question in such respects as maintaining and safety ,etc. at the same time. Finally, choose to analyse in machining accuracy, public errand to two groundwork parts, economy and dependability that the breaker soed as to ensure is designed finally. Keywords: Hammer type breakers, hammer, intensity, tolerance 不要?jiǎng)h除行尾的分節(jié)符，此行不會(huì)被打印 - 4 - 目錄 摘要 I Abstract II 第1章 緒論 1 1.1 課題背景 1 1.2 選題分析 1 1.3 國(guó)內(nèi)外現(xiàn)狀 1 1.3.1 國(guó)內(nèi)發(fā)展情況 1 1.3.2 國(guó)外發(fā)展情況 2 第2章 原理及其設(shè)計(jì)方案的確定 3 2.1 破碎機(jī)的結(jié)構(gòu)及原理 3 2.1.1 破碎原理 3 2.1.2 破碎機(jī)的主要結(jié)構(gòu) 3 2.2 設(shè)計(jì)方案 4 2.3 本章小結(jié) 4 第3章 錘式破碎機(jī)的電動(dòng)機(jī)功率的計(jì)算和選擇 5 3.1破碎機(jī)電動(dòng)機(jī)功率的計(jì)算 5 3.1.1 綜合各種因素計(jì)算功率 5 3.1.2 根據(jù)生產(chǎn)實(shí)踐以及引用經(jīng)驗(yàn)公式計(jì)算電動(dòng)機(jī)功率 6 3.2 電動(dòng)機(jī)型號(hào)的選擇 7 3.3 本章小結(jié) 7 第4章 錘式破碎機(jī)的主要機(jī)構(gòu)參數(shù)的 8 4.1 轉(zhuǎn)子部分結(jié)構(gòu) 8 4.2轉(zhuǎn)子轉(zhuǎn)速的確定 8 4.3轉(zhuǎn)子軸的設(shè)計(jì) 9 4.3.1轉(zhuǎn)子軸尺寸設(shè)計(jì) 9 4.3.2轉(zhuǎn)子軸的校核 11 4.4錘頭參數(shù)的設(shè)計(jì) 12 4.4.1錘頭質(zhì)量確定的理論分析 12 4.4.2錘頭質(zhì)量參數(shù)的確定 14 4.5帶傳動(dòng)部分的設(shè)計(jì) 16 4.5.1 設(shè)計(jì)步驟和方法 16 4.5.2 帶輪的設(shè)計(jì) 18 4.6圓盤(pán)的設(shè)計(jì) 19 4.7角接觸球軸承的選擇及校核 20 4.8鍵的選擇及校核 20 4.8.1轉(zhuǎn)子上鍵的校核 21 4.8.2皮帶輪上鍵的校核 21 4.9本章小結(jié) 21 第5章 電渦流傳感器的選擇、功能原理及其結(jié)構(gòu) 23 5.1選擇電渦流傳感器 23 5.2電渦流傳感器工作的原理 23 5.3電渦流傳感器結(jié)構(gòu) 25 5.3.1探頭結(jié)構(gòu) 25 5.3.2延伸電纜 25 5.4本章小結(jié) 26 結(jié)論 27 致謝 28 參考文獻(xiàn) 29 附錄 30 附錄 Talk single section of selection of hammer type crusher hammer head Abstract This article introduces design, manufacture and material selection of a new generation of hammerhead hammer crusher. Keywords: Crusher hammering head, design, manufacture, materials. After Western Europe cement has appeared in the industry, more than 20 years up to now to single section of shock new generation type hammer type crusher, and more than twenty years, it was from the design of technology structure, and making and material nature to choose etc, what got constantly is perfect and have become the equipment that the broken efficiency is the highest, universally popularizes and applies in its advanced in abroad many industry cement plant and limestone mine workshop. And technology broken with one level replaced the broken technology of two levels or three levels which over a long period of time taken over, and achieved better effect. Broken technology was simplified in the emergence of broken technology of one level, and builds or aspect transforming the limestone mine, reducing broken(ly) carrying and gathers dust etc that the equipment and the factory building and centre stores in a warehouse the building the input of feed container, and practises thrift the engineering construction investment always, and still practises thrift the mass electric energy in production, and reduced the operation of equipment maintenance man, and gained better technology economy effect. The eighties after entering our country has been universalized in to apply in builds and transforms in the big-and-middle-sized cement plant of our country the broken technology of this kind of one level. This kind of new type crusher is on the foundation of past crusher, and from the structure, the material is chosen constantly to improve to develop and is become the design and manufacturing of major part, for example Beijing heavy duty machinery factory recommends MB's mould hammer type crusher of German O&K company, and the special design was done in its broken cavity, not only having to lash broken and counterattacks the broken function, but also has the fixed anti- bullet function, and the electromagnetism which can be mixed in the limestone is inhaled the metal thing that the iron was not absorbed instead in the fixed scope leaping out. If in Fujian Longyuan cement plant twice load test runs in revolving, successively one thickness 35mm, heavily reaches 38 kilograms the ring form dunnage 6 kilograms one heavy indisputable instead leaps out, the more typical is in the new cement plant of Hubei Province China, and the shovel tooth with power shovels of 4 cubic metres safe(ly) instead leaps out, and the machine does not suffer any harm. Is old style hammer type crusher can not compared, and his reliability and service life also are the generally old style hammer type crusher is not had to harsh nature of his operating mode condition to its chiefly work part - hammer head, and have become the hinge of this crusher. The next is done some brief introductions to this kind of crusher hammer head. 1 hammer decideing on of head Austria human relations phases of Germany are level - MAMMUT ( abbreviation MB's mould ) crusher of Ke Peier company ( O&K ), and Denmark Shi Misi company ( FLS ) EV's crusher; The crusher more than the use is all very laid stress on the chemical composition of limestone with HES and HDS's mould of big vast fort company ( KHD ) of Germany, especially dissociates the content of silica content, physics function, clay soil and moisture content, and the ore structure condition, thus comes to think over material nature and his structure of his hammer head. 2 hammers hot conditionss inside the broken cavity of head Owing to the hammer hot conditions of the inefficacy of head and broken is closed closely, so the design of hammer head and making must be thought over his work circumstances in smashing something to pieces cavity. The usual ore enters smashing something to pieces behind the cavity, and all suffers the strong shock arranging of high-speed operation hammer head with the fixed drop in elevation. The crusher of new type, not only his shocks is energetically strong, but also makes the thing expects at hammer frame and the hammer in the motion, gains kinetic energy, another shock board ( calling counterattacking the board ) inside the broken machine cavity of shock at a high speed, then and from the shock anti- rebound of board to the hammer the broken area, the so repeated smashs something to pieces and mills, the ore constantly along his the joint itself layer and smashs something to pieces in interface and natural crack and loose, and until his size is smaller than the comb with a double-edged fine-toothed comb sieve interval, blows off the organism. 30 - 33 meters are generally taken to the linear velocity of these hammers head work / second, the linear velocity of the EV of Denmark Shi Misi company mould hammer type crusher hammer head the high(ly)est took 39 meters once / second, it is 4 - 6 times per second that a frequency which hit is participated in by every hammer head. 3 hammers type crusher hammer dead analyses of head According to the mentioned above circumstances, the new hammer type crusher hammer head itself is bearing centrifugal force when work, and does being used the shock of ore and mills, and is bearing the shock of the strong reacting force of ore, still having rub stress and drawing which come into contact with between hammer hole and hammer axle power, these destruction factors that the power is the hammer head have the wear under the general status and split two kinds of destruction circumstances, and the wear version is the normal appearance, and it occurs the rub Mian between surface and top and hammer hole and the hammer axle of hammer head, and the fine hammer head really weares and teares, and is wear and tear losing efficacy putting off as far as possible. The hammer head splits that the destruction right and wrong is green, and it chiefly is the unsuitable and defect of manufacture technology owing to the qualitative selection of material, and makes that intensity and plasticity of hammer head itself is inadequate, and gives rise to the stress concentration, or the use unsuitably waits for the factor and creates. So the hammer of the high quality head must possess the sclerosis effect of hard surface or good, and still will possess enough internal intensity and good plasticity theory function, and can suit repeatedly the broken work of shock inside the broken cavity, and realize that his wear is small, the sunday purpose. 4 The material nature of hammers heads and manufacturing A now hammer type crusher hammer material nature of use is a lot, and it is also a lot of to make the method, and resembles several kinds of material nature greatly but belonging to casting, forging, surfacing and the combination four basically, and appears to incite somebody to action in common use to give an example that the introduction is following: 4.1 high manganese chromium steel casts the hammer High manganese chromium steel more is suitable in the acute shock and works with the wear operating mode than potassium steel, and it is not having a magnetism austenitic steel, and being the hig strength abrasion resistant steel of model, possessing high toughness, it is on the foundation of potassium steel to tensile strength and percentage elongation, and joining the chromium of one fixed quantity, can raise his original hardness, and especially raise the subduing limit and cannot harm in tensile strength and percentage elongation, raising the wear resistance and avoid his plastic deformation, each producer all worked out oneself the standard, and bys way of oneself technology and interior accuse quota, making the cast after the pliable but strong processing of water, and gains the complete austenite metallographic structure, and utmost was controlled the formation of carbide, and hammer that appears with Germany O&K company, Denmark F.L.SMIDTH company and Japanese maize ironworker the material nature chemical composition is expressed showing as follows. 4.2 the alloy steel forges the hammer head Because the fact that the hammer not only need to be able to bear or endure the shock of strong power, and will wear-resisting(ly) lose, and works as the limestone grade belonging to medium hardness, even when soft partially, generally the cold hardening effect of high manganese chromium steel is unclear, German O&K company MAMMUT's crusher with big vast fort ( K.H.P ) HES's crusher all selected the hammer of alloy steel forging, the heavy machine factory of Beijing recommends after MAMMUT's crusher license technology of German O&K company, his produces MB's Composition and hardness are cast to high manganese chromium steel 4.3 compound material hammer head Owing to the hammer end ministry of head receives that the power is different with the receiving power of hammer bearing hole place, and material nature which in front selected is laid stress on the requirement of hammer end head, the to this end Ma Getuo of the Belgium ( Mogoffeoax ) company according to his two aspects receives power different(ly) to ask different(ly), and produces one kind of high chromium iron casting hammer head of compound casting. It is on the hammer handle in the alloy structural steel forging, and the ministry that makes the hammer head receive to lash rubs is piece for the high chromium iron casting material to high chromium iron casting on the compound casting, and making the hammer handle partly have the plasticity enough, and a hammer head end ministry possesses very high hardness and thewear resistance, and they in all ask very strict(ly) at the aspect of smelting of material and heat treatment, and after the high chromium iron casting part quenches as a result of high temperature and the low temperature tempering, his remnants austenite organisations asks controlling in the tiny scope, and that its chemical composition reaches casts like the sketch map. The ESCO company of the United States developed the crusher hammer head of one kind of type making up like the graph, and his characteristic is can change the lashing the part rubbing of hammer head end ministry quickly, and maintenance person need not whole hammer of the demounting head, only dismantling to load to lash the melting the axle of head, namely can change the hammer head quickly, his hammer head also can be made high chromium iron casting, and according to introduces when the hammer handle wearing and tearing when discarding, it probably changed 10 - 30 pairs of hammers heads, and when changing the hammer head, the metal genuinely thrown away is only occupied 25% - 35% of whole hammer nose heavy capacity every time, it is thus clear that more economical. 4.4 the hammer head is repaired in the surfacing after the wear Alloy steel to weares and teares after the fixed level forges hammer head and alloy steel and casts the hammer head, and has the user of condition can adopt the surfacing restoration. The influence owing to thermal effect to his metal organisation is not easily controlled potassium steel and high manganese chromium steel, therefore the surfacing is hard to achieve satisfied effect. 5.Reasonable lectotype of 5 hammers heads Artificer must fully understand the natural conditions that the thing will smashing something to pieces is expected when designing one Taiwan limestone crusher, if fully income material size and hardness that the thing is expected dissociates content, clay soil and the moisture content content of silica etc, and is reasonably selected the geometric form size and the weight of hammer head, with his hammer of guaranty dynamics working. 6.about hammer head judging of good and bad. The good and bad of hammer type crusher hammer head is whether, and being usually processing bys way of certain requirement of one size capacity and the hammer head wears and tears judging, two kinds of numerical value that his is judged are following Type in single hammer G-- weight ( kg ) N--'s crusher is installed hammer head quantity K--'s every hammer head is permitted to wear and tear partly to occupy the weight of whole hammer head limestone processing capacity ( t ) than the one set of hammer ( % ) T—head W-- wears and tears than ( gram / ton ) Wear capacity that every hammer head is permitted generally being 12 - 15% to surpass 17%, because a hammer loss is too much, the interval that makes between hammer shock board and the comb with a double-edged fine-toothed comb strip is big excessively, will influence the product size, as for user prepare the forging of the surfacing restoration hammer, but Ying Zaiqi's wear partly is smaller than 10% before repairs. Hoping the cement plant, and recommended 7090 moulds MAMMUT's crushers of German O&K company once, the flint tubercle of jade marrow and uneven is kept in the mouth in this factory limestone mine, not only forcibly and dissociates that silicacontent belongs to one kind of ore that broken nature is wronger for 2.04 - 8.9%,, but the one set high manganese chromium steel hammer head of this Taiwan crusher first wife deals with wears and tears than only serving as the 0.56 gram / ton limestone and created the very good beneficial result behind more than 1500 thousand tons of limestones. Otherwise, if not thinking over that the thing material character draws sound, to use the high manganese chromium steel hammer head blindly, but the endless ideal of his effect. This the kind of hammer head that the same that like our country recommended in certain cement plant of south crusher was used was only dealt with not wearing and tearing to 300000 tons of limestones discarding. The compound hammer head of high chromium iron casting in is spoken being fit for in the softer limestone on theory, and does not still see the report of concerned economic performance though having used in some cement plants. When the press intensity of most of limestone is smaller than 140MPa, so uses the high manganese cast steel, uneasy fully hardness that gets potassium steel should gain when the cold hardening and early stage is worn and torn, and the alloy steel forges the hammer head, and because of his whole that to possess strong(ly) pliable but strong and hard lashing the surface, suiting the limestone of broken medium hardness, this the kind of forging hammer head that Beijing heavy duty machinery factory produced after recommending the manufacture technique of German O&K company, and passing the test in the use of new cement plant MB's crusher of China, and fully having proved his effect well, his wears and tears than is smaller than the 1 gram / ton limestone. In speaking on overall, raising the hammer of single section of school assignment type crusher hammer service life, not only manufacturing plant will pay attention to pledging manufacture technology and raising hammer qualitative mechanical performance and the quality of material, and also user also will attach importance to the hammer the science lectotype, accomplishes " because of the material bringing into effect the hammer " with the management of reasonable science, completely raises the hammer service life. 談單段錘式破碎機(jī)錘頭的選擇 摘 要 重點(diǎn)介紹新一代錘式破碎機(jī)錘頭的設(shè)計(jì)、制造及材質(zhì)選擇。 關(guān)鍵詞 破碎機(jī)錘頭　設(shè)計(jì)　制造　材質(zhì) 新一代單段沖擊式錘式破碎機(jī)在西歐水泥工業(yè)中出現(xiàn)后,至今已二十多年,廿多年來(lái),它從工藝結(jié)構(gòu)的設(shè)計(jì),制造及材質(zhì)選用等,得到了不斷的完善,已成為破碎效率最高的設(shè)備,它已在國(guó)外許多工業(yè)發(fā)達(dá)的水泥廠及石灰石礦山車間普遍推廣應(yīng)用。并且以一級(jí)破碎的工藝,取代了長(zhǎng)期襲用的二級(jí)或三級(jí)破碎工藝,達(dá)到了較好的效果。一級(jí)破碎工藝的出現(xiàn),簡(jiǎn)化了破碎工藝,在新建或改造石灰石礦山方面,減少了破碎輸送、收塵等設(shè)備及廠房、中間倉(cāng)儲(chǔ)料斗的筑投入,節(jié)約工程建設(shè)總投資,而且在生產(chǎn)中還節(jié)約了大量的電能,減少了設(shè)備的操作維修人員,取得了較好的技術(shù)經(jīng)濟(jì)效果。這種一級(jí)破碎工藝,八十年代進(jìn)入我國(guó)后,已在我國(guó)大中型水泥廠建設(shè)和改造中普及應(yīng)用。 這種新式破碎機(jī),是在舊的破碎機(jī)的基礎(chǔ)上,從結(jié)構(gòu),主要零件的設(shè)計(jì)、制造,材料選用上不斷改進(jìn)發(fā)展而成的,比如北京重型機(jī)械廠,引進(jìn)德國(guó)O&K公司的MB型錘式破碎機(jī),它的破碎腔作了特殊設(shè)計(jì),不但有沖擊破碎和反擊破碎的功能,而且有一定的反彈功能,能把混在石灰石中的電磁吸鐵未吸取出的金屬物在一定范圍內(nèi)反彈出來(lái)。如在福建龍巖水泥廠的兩次載荷試車運(yùn)轉(zhuǎn)中,先后把一塊厚度35mm,重達(dá)38公斤的環(huán)狀襯板及一塊重6公斤的鐵塊反彈出來(lái),更加典型的是在湖北華新水泥廠,將一個(gè)4立方米電鏟的鏟牙安全的反彈出,機(jī)器沒(méi)有受到任何傷害。它的主要工作零件——錘頭,其工況條件的嚴(yán)酷性,是老式錘式破碎機(jī)所無(wú)法比擬的,而其可靠性和使用壽命,也是一般老式錘式破碎機(jī)所不具備的,已成為這一破碎機(jī)的關(guān)鍵。下面對(duì)這類破碎機(jī)錘頭作一些扼要介紹: 1　錘頭的選定 德國(guó)的奧倫期坦-科佩爾公司(O&K)的MAMMUT(簡(jiǎn)稱MB型) 破碎機(jī),丹麥?zhǔn)访芩构?FLS)EV破碎機(jī);德國(guó)洪堡公司(KHD)的HES和HDS型,使用以上破碎機(jī),都十分注重石灰石的化學(xué)成分,特別是游離二氧化硅含量,物理性能,粘土及水分的含量,及礦石結(jié)構(gòu)條件,從而來(lái)考慮其錘頭的材質(zhì)和其結(jié)構(gòu)。 2　錘頭在破碎腔內(nèi)的工作條件 由于錘頭的失效與破碎的工作條件密切關(guān),所以錘頭的設(shè)計(jì)與制造必須考慮其在破碎腔中的工作情況。通常礦石進(jìn)入破碎腔后,都以一定的落差受到高速運(yùn)轉(zhuǎn)錘頭的強(qiáng)列沖擊。新型的破碎機(jī),不但其沖擊力強(qiáng),而且使物料在錘架和錘頭的運(yùn)動(dòng)中,獲得動(dòng)能,高速?zèng)_擊破機(jī)腔內(nèi)的另一沖擊板(稱反擊板),然后又從沖擊板反彈回到錘頭的破碎區(qū),如此反復(fù)的破碎、銑削,礦石不斷沿著其本身的節(jié)理層、界面和自然裂隙而疏松破碎,直到其粒度小于篦篩間隙,排出機(jī)體。這些錘頭工作的線速度,一般取30～33米/秒,丹麥?zhǔn)访芩构镜腅V型錘式破碎機(jī)錘頭的線速度最高曾取39米/秒,每個(gè)錘頭參與打擊的頻率是每秒4～6次。 3　錘式破碎機(jī)錘頭失效的分析 根據(jù)上述情況,新型的錘式破碎機(jī)錘頭,在工作時(shí)本身承受著離心力,作用于礦石的沖擊、銑削,又承受著礦石的強(qiáng)烈的反作用力的沖擊,還有錘孔與錘軸之間接觸的磨擦應(yīng)力和拉伸力,這些力是錘頭的破壞因素,一般情形下有磨損和斷裂兩種破壞情況,而磨損型式是正?，F(xiàn)象,它發(fā)生在錘頭的表面和頂端及錘孔和錘軸間的磨擦面,優(yōu)良的錘頭不是不磨損,而是將磨損失效盡可能地推遲。錘頭的斷裂破壞是非正常的,它主要是由于材質(zhì)的選擇不當(dāng)及制造工藝的缺陷,使錘頭本身的強(qiáng)度及塑性不足,產(chǎn)生應(yīng)力集中,或使用不當(dāng)?shù)纫蛩卦斐?。所以高質(zhì)量的錘頭,必須具有堅(jiān)硬的表面或良好的硬化效果,還要具有足夠的內(nèi)部強(qiáng)度和良好的塑性力學(xué)性能,才能在破碎腔內(nèi)適應(yīng)反復(fù)沖擊破碎的工作,實(shí)現(xiàn)其磨損小,效率高的目的。 4　錘頭的材質(zhì)及制造 當(dāng)今錘式破碎機(jī)錘頭使用的材質(zhì)很多,制造方法也很多,但基本屬于鑄造、鍛造、堆焊和組合四大類若干種材質(zhì),現(xiàn)將常用的舉例介紹如下: 4.1　高錳鉻鋼鑄造錘頭 高錳鉻鋼比高錳鋼更適用于劇烈的沖擊和磨損工況下工作,它是一種無(wú)磁性?shī)W氏體鋼,是典型的高強(qiáng)度耐磨鋼,具有高的韌性,抗拉強(qiáng)度和延伸率,它是在高錳鋼的基礎(chǔ)上,加入一定量的鉻,可以提高其原始硬度,特別是提高屈服極限而無(wú)損于抗拉強(qiáng)度和延伸率,提高耐磨性而避免其塑性變形,各制造商都制訂了自己的標(biāo)準(zhǔn),通過(guò)自己的工藝技術(shù)和內(nèi)控指標(biāo),使鑄件在水韌處理后,獲得完全的奧氏體金相組織,并且最大限度地控制了碳化物的生成,現(xiàn)將德國(guó)O&K公司、丹麥F.L.SMIDTH公司及日本粟米鐵工所的錘頭材質(zhì)化學(xué)成分表示如下表。 4.2　合金鋼鍛造錘頭 由于錘頭不僅需要耐強(qiáng)力的沖擊,而且還要耐磨蝕,當(dāng)石灰石品位屬于中等硬度,甚至偏軟時(shí),一般高錳鉻鋼的冷作硬化效果是不明顯的,德國(guó)O&K公司MAMMUT破碎機(jī)和洪堡(K.H.P)HES破碎機(jī)均選擇了合金鋼鍛造的錘頭,北京重型機(jī)器廠引進(jìn)德國(guó)O&K公司的MAMMUT破碎機(jī)許可證技術(shù)后,其生產(chǎn)MB系列錘式破碎機(jī)錘頭,根據(jù)礦石條件也選用鍛 造材質(zhì),其工藝過(guò)程為: 精煉合金鋼 注成鋼錠—→鍛造開(kāi)坯—→模鍛成型—→調(diào)質(zhì)處理—→加工錘孔等—→錘頭打擊區(qū)熱處理—→無(wú)損探傷。在鋼水的冶煉和注錠過(guò)程中,除要求控制硫、磷的含量外,還要注意其他成分的偏差量,和氫、氧等有害氣體。合格的鋼錠,在水壓機(jī)上開(kāi)坯拔長(zhǎng),然后在16噸的高速錘或10噸模鍛機(jī)上鍛成規(guī)定的幾何形狀。錘頭的調(diào)質(zhì)熱處理十分關(guān)鍵,要求其整體抗拉強(qiáng)度在850MPa以上,而且要求有相當(dāng)?shù)捻g性和塑性。在錘孔加工后,對(duì)錘端打擊區(qū)進(jìn)行表面淬火,不僅要求其表面硬度達(dá)HB410～460,而且其內(nèi)部的硬度梯度,要求嚴(yán)格控制在公差帶內(nèi),因此每批錘頭除選一件在錘孔附近取試件進(jìn)行綜合機(jī)械測(cè)試外,還要任選一件沿錘頭對(duì)稱中心剖開(kāi),按規(guī)定的距表面距離,分等線距地檢測(cè)其硬度,要求其硬度梯度的變化在規(guī)定的公差帶范圍之內(nèi),這批錘頭硬度才算合格。最后逐一進(jìn)行超聲波及磁粉探傷,以確保錘頭內(nèi)部和外 部均不存在缺陷和裂紋,保證錘頭質(zhì)量萬(wàn)無(wú)一失。這些鍛件的材質(zhì),德國(guó)O&K公司選用450鋼,洪堡(K.H.D)則選用30CrMo9V,美國(guó)ES-CO公司,選用12S。以上三種牌號(hào)材料,均含有不同比例的鉻(Cr)、鉬(Mo)等合金元素。 表1 高錳鉻鋼鑄造成分和硬度 4.3　復(fù)合材料錘頭 由于錘頭的端部受力與錘軸孔處的受力不同,前面選擇的材質(zhì),注重錘端頭部的要求,為此比利時(shí)的馬格托(MOgoffeox)公司,根據(jù)其兩個(gè)方面受力不同要求不同,生產(chǎn)一種復(fù)合鑄造的高鉻鑄鐵錘頭,它是在合金結(jié)構(gòu)鋼鍛造的錘柄上,復(fù)合澆鑄上高鉻鑄鐵,使錘頭受沖擊磨擦的部份為高鉻鑄鐵材料,而使錘柄部分有足夠的塑性,錘頭端部具有極高硬度和耐磨性,它們?cè)诓牧系囊睙捄蜔崽幚矸矫娑家笫謬?yán)格,高鉻鑄鐵部分經(jīng)過(guò)高溫淬火、低溫回火后,其殘余奧氏體組織,要求控制在極小的范圍內(nèi),它的化學(xué)成分及鑄造如示意圖 表2復(fù)合材料錘頭化學(xué)成分表 美國(guó)的ESCO公司,研制了一種組合式的破碎機(jī)錘頭如圖示,其特點(diǎn)是能快速更換錘頭端部的沖擊摩擦部分,維修者不必卸下整個(gè)錘頭,僅拆裝沖擊頭部的銷軸,即可快速更換錘頭,其錘頭也可制成高鉻鑄鐵, 據(jù)介紹當(dāng)錘柄磨損到報(bào)廢時(shí),它可能已更換了10～30付錘頭,每次更換錘頭時(shí),真正扔掉的金屬,僅占整個(gè)錘頭重量的25%～35%,可見(jiàn)是較經(jīng)濟(jì)的。 圖1　復(fù)合材料錘頭 圖2　可快速更換的組合錘頭 4.4　磨損后的堆焊修復(fù)錘頭 對(duì)磨損到一定程度后的合金鋼鍛造錘頭及合金鋼鑄造錘頭,有條件的用戶可以采用堆焊修復(fù)。高錳鋼及高錳鉻鋼,由于熱效應(yīng)對(duì)其金屬組織的影響不易控制,因此堆焊難以達(dá)到令人 滿意的效果。德國(guó)O&K公司,對(duì)于合金鋼鍛造錘頭采取堆焊的方法是:將它分緩沖層、溶焊層、加強(qiáng)層三層進(jìn)行焊復(fù),每層所用的堆焊材料是不同的,在實(shí)施堆焊之前,錘頭焊接面必須清洗干凈并進(jìn)行予熱,在實(shí)施堆焊過(guò)程中為體溫度應(yīng)控制在350℃～400℃以內(nèi),焊后應(yīng)用保溫?zé)岵牧暇徖?防止因冷卻太快而產(chǎn)生裂紋,這種堆焊可不拆卸錘頭,在機(jī)內(nèi)進(jìn)行,其三種堆焊材料的成分及堆焊修復(fù)示意圖如下: 表2 堆焊材料的化學(xué)成分 圖3　錘頭的堆焊修復(fù) 5　錘頭的合理選型 在設(shè)計(jì)一臺(tái)石灰石破碎機(jī)時(shí),設(shè)計(jì)者必須充分地了解將要破碎物料的自然條件,如物料的最大入料粒度、硬度,游離二氧化硅的含量,粘土及水分含量等,合理選擇錘頭的幾何形狀尺寸及重量,以保證其錘頭工作的力度。 6　關(guān)于錘頭優(yōu)劣的判定 錘式破碎機(jī)錘頭的優(yōu)劣與否,通常是通過(guò)某一粒度要求的處理量及錘頭的磨耗來(lái)判定,其判定的兩種數(shù)值如下 式中G——單個(gè)錘頭的重量(kg) n——破碎機(jī)安裝錘頭數(shù)量 K——每個(gè)錘頭允許磨損部分占整個(gè)錘頭的重量比(%) T——一套錘頭的石灰石處理量(t) W——磨耗比(克/噸) 每個(gè)錘頭允許的磨損量,一般為12～15%不得超過(guò)17%,因?yàn)殄N頭損失過(guò)多,使錘頭沖擊板及篦條之間的間隙過(guò)大,將影響產(chǎn)品粒度,對(duì)于用戶準(zhǔn)備堆焊修復(fù)的鍛造錘頭,則應(yīng)在其磨損部分小于10%之前進(jìn)行修復(fù)。 冀中水泥廠,曾引進(jìn)德國(guó)O&K公司的7090型MAMMUT破碎機(jī),該廠石灰石礦含玉髓和不均勻的燧石結(jié)核,不僅硬且游離二氧化硅含量為2.04～8.9%,屬于一種破碎性較差的礦石,可這臺(tái)破碎機(jī)原配的一套高錳鉻鋼錘頭處理了150多萬(wàn)噸石灰石后磨耗比僅為0.56克/噸石灰石、創(chuàng)造了非常好的效益。反之,如不考慮物料品質(zhì)的引響,一味使用高錳鉻鋼錘頭,其效果則不盡理想。如我國(guó)南方某水泥廠引進(jìn)的同類破碎機(jī)所用的此種錘頭,僅處理了不到30萬(wàn)噸石灰石就磨損報(bào)廢了。 高鉻鑄鐵的復(fù)合錘頭,從理論上講較適合于較軟的石灰石,雖已在一些水泥廠使用,但還沒(méi)有見(jiàn)到有關(guān)經(jīng)濟(jì)效益的報(bào)導(dǎo)。 大多數(shù)石灰石的擠壓強(qiáng)度小于140MPa,所以使用高錳類鑄鋼時(shí),不易充分得到高錳鋼在冷作硬化時(shí)應(yīng)取得的硬度而早期磨損,而合金鋼鍛造錘頭,因其具有強(qiáng)韌的整體和堅(jiān)硬的沖擊表面,較適于破碎中等硬度的石灰石,北京重型機(jī)械廠在引進(jìn)德國(guó)O&K公司的制造技術(shù)后生產(chǎn)的這種鍛造錘頭,在華新水泥廠MB破碎機(jī)的使用中,經(jīng)過(guò)考驗(yàn),已充分證明其效果良好,其磨耗比小于1克/噸石灰石。從總體上講,提高單段作業(yè)的錘式破碎機(jī)錘頭的使用壽命,不僅制造廠要注意保證制造工藝和提高錘頭的材質(zhì)的機(jī)械性能和質(zhì)量,而且用戶也要重視錘頭的科學(xué)選型,做到“因材施錘”以合理科學(xué)的管理,全面地提高錘頭的使用壽命。