Brokenequipmentwearandwear-resistingmaterialFenmodevelopmentAbstracttartingfromwearinghilureanalysis，theauthorintroducesthestructureandshape，mutualmatchingrelation，manutacturingengineeringofwear—resistingmaterisls，qualitycontrolandapplica—tioncharacteristicsofdamageablepartsincrushingandgrindingsystemandenumerateschemicalcornportentsandmechanicalpropertiesoftypicalwear-resistingmaterialsathomeandabroad．Thedevelopmeritofwear—resistingmaterialsisalsogiveninthisarticle．KeyWords：crushing，grinding，damageableparts，wear-resistingmaterials1IntroductionMetallurgicalmining,buildingmaterials,thermalpowergeneration,chemical,coal,andotherindustrialsectors,theneedforvariousbrokenFenmoequipment.Thesepiecesofequipmentvulnerablegroupsaffectedbytheground,tryingprotected,materialwearandtear,theannualconsumptionofthemetal.Forfeedingtothecementindustry,1994productionof405milliontonsofcementnationwide.BallmillChenbancategory,Breakerscategorydepletionofmetalabout300~350g/tcement;Mostmedium(ball,above)500g/tcement,suchasyoungas1994onthecementindustryconsumed120000tChenbantypemetal,grindingbodies2omore.Accordingtorelevantstatistics,black,coloredmetalminesexertionmore,theNationalexertionBreakers,ballmillliningprotectedmetalabout50000t,about130kmmediummetalwithatotalvalueof80billion.Materialconsumptionisreflectedinenergyconsumption,thussavingenergyandreducingconsumptionofmaterialsmetalsanimportantaspectofaverycleareconomicandsocialbenefits.Atthesametimeasaresultofthereplacementofforcedrelocationofparkingtimeinthecementindustryaboutthetotalparkingtime55~50,representinganincreaseofwearandtearofequipmentmaintenanceworkload60~65,withbrokenequipmentcraftsFenmorapiddevelopmentoftechnology,withincreasinglylarge-scaleequipmentdevelopmentanduseofnewwear-resistingmaterialgrowingimportance.2brokenFenmoequipmentwearandtearFenmobrokenequipmentwearandtearcanbedividedintointernalfactorsandexternalfactors.Internalfactorsincludethequalityofmaterialsmetallurgy,chemicalcomposition,metallographyandmechanicalpropertiesofmaterialsIexternalfactorsincludingthehardnessandtoughness,sizeandedgesandcornersRuiduoetc.Sizepiecesdependingonwhetherthematerialdurableresistancetowearandtearabilitytoresistfatiguewearcapacity-lungmachineandploughscutcapacity.ThesizeofseveralmajorpiecesofequipmentbrokenFenmowearasummaryanalysis.Brokenanti-aircraftteethevery.2.1PlateJaw-Breakersteethplatesworntoholescut-worn.JiangsuChangshuquarriestousePZ250~500-jawstyleBreakersteethprotected,forexample,theteethareprotectedbythematerialshandlingwaterstandardshighmanganesesteelfasteners.Inscanningcallyouthfulobservationteethwrenchedhimselffacecanbeseen,teethprotectedbysqueezingoutasmuchofthesurfacematerial,followedbyapressureabrasivetonguepushinghimselfface,canbeseenintheuppersurfaceofmanyabrasiveedgesbecausethemarksarecausedbyshort-rangesliding,andmayseeaslightcracksteethboardsurface,seefigure1.Afteranalysis,teethwrenchedwornmainlyabrasiverelativeteethboardshortsliding,cuttingmetalgrindingscrapandabrasiverepeatedlysqueezecausedteethprotectedmaterialsondeformation,resultinginthemetalmaterialsofffatigue,lossofskillstoteachthecourseare:(1)materialsrepeatedlysqueezeholecutteetharrangedintheteethprotectedareasurface,orinmetalsqueezethehighlightsrootsformmicrocracks,linkedtothecontinuedexpansionofmicro-cracks,causingthesurfaceofmetalmaterialsseparated,forminghimselfcrumbs.(2)Sectionobjectsrepeatedlysqueeze,causingteethwrenchedmetalmaterialswerepartiallyclosedorresidentstorevealthefragmentationorresidentstorevealsomeofthematerialsandtheimpacttosqueezeoffadifficultscrap(3)materialrelativeteethshort-rangeslidingpanels,adifficultscrapcarbideteethboards.Thereforeteethfromwear-resistingmaterialcontrolpanelswornmainlyhardnessandresilience.Hardmaterials,materialssqueezeshallowdepth,materialdeformationsmall,short-rangeslidingcuttingmaterialsvolumeofthematerialisalsogoodresilienceofsmallmaterials,astrongabilitytoresistfracture,theimpactmayberemovedsqueezeprocessbrittlenessfracture,raisinganti-fatiguedeformationshellcapacity.Jaw-Breakersdifferentsizespecifications,feedgranularity,Ruiduodifferentpanelsofthesqueezingoutteeth,differentimpactsoflargeandmedium-sizedsqueezepressure,apartfromthematerialtoresistpressureandtoresistsqueezeslidingbrackets,shouldalsoconsidertheimpactoftheimpactandbendingstressthelargeteethboardcompositionshouldusehighresilience,goodoverallperformancematerials.Fromtheaboveanalysisshowswearineffectiveforteethboardmaterialshouldchoosehardnesshighresistancematerialstosqueeze,lungmachinefailures,thechoiceofmaterialssufficienttoresistcuttingBoresiliencecutimpactfatiguefailure.Atthesametimetoimprovethestructureofboardsfromtheteeth,andtoothplatestoreducetherelativeslidingmaterials,usefulnotonlyforincreasingproductivitybutalsotoimprovethemateriallifeuseful.2.2hammer-BreakersdeadDifferentspecificationshammer-Breakers,deadshapeandsizevary,itisgenerallythoughtthatthedead90~125kgforlarge,25kgFollowingisasmall,andtherestformedium.Dazhongplantgeneraluse25~50kgdead.Thedeadandsizesandtheuseofthestateofdifferentconditions,thewearandtearofitsfailurevary.Thedeadwear,withtheimpactofthecut-cut,accompaniedbyheavylungmachinewear.ExternalitiesforimpactcratersanditsworncuttingplowGap.Thedeadwearandtearofthemainwaystoattack,sododeadpeopleaccustomedtothechoiceofhighmanganesesteelmaterials.(1)Thefollowingdeadone2kgBecauseofitsextremelysmalljumping,Jiagongyinghuacannotgivefullplaytotheroleofhighmanganesesteel,resistancetoabrasionfromideal,suchasbrokenfeldspar,Liezhimeiandblastfurnaceslagandothermaterials,deadinafewdaysorevenafewclasses,somefailures.Itwasreportedby5.8kgto11.5kgdeadandcementusedtoweardeadaftermutilatedbodylapseanalysisrevealedtwodeadJiagongyinghuaresultsarepoorsurfacehardeningcurveshowninfigure2.Thewearprocessissmalldeadmaterialsontheonehandsmallenergyshocksdead,ametalsurfacedeformationandplasticityEmblemcracks.Justchangemanytimesintheexpansionofcracks,metaldebrisparticlesformedbysqueezingout,leadingtoshockswear;Ontheotherhandmaterialstipssurfacematerialsinacertainlawisthepowertoinfluenceandroleofthesurfaceofmetalmaterialshavelungmachine,washed,wornmetalsurfaces,butbecauseoftheimpactofpower,highmanganesesteeltobeJiagongyinghua.Therefore,itisnecessarytochooseacertainresiliencetothehighhardnessofthematerialcanleadtoasubstantialincreaseusefullife.(2)50kgclassdeadBecauseofitsgreatimpact,highmanganesesteelmaterialsusinghighresilience,itsperformancehasbeenJiagongyinghuamustplaydeadtowear,impactandcut-cut,micromachiningwithheavywearandtear,wearmicroexternalitiesperformanceforimpactcratersandcuttingplowGap.However,ifthematerialconditionsofthestatearedifferent,thesameistheuseofhighmanganesesteeldeadalsoabigdifference.ShaanxiRiveristhesameascementplantproduction12P50kgclasshighmanganesesteeldeadineternalplantonlyapplications2~3monthsfailures;CementplantinYaoxianavailable8~11months.DianjingguanchaeternalintheplantdeadwornsurfacemainlycuttingplowGap,impactcratersexistontheexpiryoftheirwornmainlybycuttingmechanismstowearandtear,accompaniedbyimpact.Analysisbecausetheplantlimestonematerials,includinglargequantitiesofmud,smallgranularitytoreducetheimpactload,highmanganesesteelprocessinghardnessless,andoftenwithhighhardnessofthematerialsilicaslateofhighmanganesesteelausteniticlikeZeikowaacuminataisahardmetalknife,leavingmanycuttrench,sowearfaster.Yaoxianplantisdeadwearfacemajorimpactcraters,andasmallcutbelow,theimpactthatitiswornmainlybycuttingwearandtear,itisbecausethelimestonepiecesfortheGreatYaoxianplant,andevenly,theimpactgreat.Limestoneandtheimpactofadeadwearfacemanyimpactcraters,cratersarevisiblearoundhere.Thehighmanganesesteelhavegoodplasticity,isinabrasiveimpactoftheformationofimpactcratersandeasierplasticitydeformation;Ontheotherhand,becauseofthelargerimpactofhighmanganesesteeltobeJiagongyinghua,increaseddeformationresistance,andthusdemonstratedhigherwear-resistantability.Ascanbeseenfromtheaboveanalysis:inacut-basedcases,thehardnessofthepoetryofresistancetoabrasionleadroletosolvethisproblem,weHubeicementplantwithasuper-highmanganesesteelinthedevelopmentofhigh-resiliencepremisetenfeetofimprovingitsyieldstrength(upto450N/ram.),toincreasetheinitialhardnessHB260~300.atthesametimeimprovingitsJiagongyinghuarate,thelongevityLifesignificantlyimproved.(3)LargeBreakers90kgand125kgdeadTodoitsworkto90kgdeadparametersasshownintable1.Table1showstheaggregatesizeoftheBreakersintolarge,brokenthanlarge,highrotationalspeed,thedeadimpactofthelargeimpactonthewearandtearonmachinery.Materialshouldleadtoresiliencetocombinehardness,intensity,integratedperformance.Cementkilns,Marcht983usefromGermanyO8ⅨcompanyintroducedMB70/90-hammer-styleBreakers,90kgdeadisdoubletheoriginalmetalcasting,withhisheadhighchromiumcastiron,hammerhandlesinlowalloysteel,theuseofdeadcutoff,combiningDepartmentfracturemoreaffectednormalproduction,thethreatofwholesetsofsafetyJuly1986importsO&KcompaniesShanmetal90kgdead,theaverageuseof10monthsbroken1800000tlimestone.Tangshancementplantinthecountrydeadautopsyanalysisbookbasisandhighmanganesesteeldead,1991,throughministerialidentification.~18containingmanganesesteelupto17,mainlytoenabledeadHouda,thecenterfortheentireDepartmentgenerallymaintainitsexcellentresilience,theuseofreliable,increaseCrMoandotherelementstoimproveoverallyieldstrengthandinitialhardness,theperformanceneedsofproduction.Wearandtearontheabovedescriptiontotheimpactofthevulnerabilitytochoosematerialsandsupplementedbyotherhigh-resilienceintegratedperformance.ThewearandtearoftheballmillChenban2.3WearballmillliningplateBall(control)millsandtheChenbanbearMoqiumaterialsshocks,cut,squeezeandlungmachinemultifacetedroleofwornsurfacefeaturesisacrater,crackleandploughsGap.Andthedegreeofwearmaterialscharacteristics,size,natureRuiduolivingskills,butalsowiththeroddiametersizespecifications,Chenbanwhichparts.2.2mx6.5mtocementmillstodo,awarehouse,twopositionshighmanganesesteelsurfaceofamirrorChenbanwornphotographsshowninfigure3andfigure4.PhotofromawarehouseintheforeseeableChenbanmanyploughsGapandspallingpit,becauseawarehousefor70~80mmaverageballDrive,thelargestballto90~100mm,averagegranularity25rammaterials,thelargestupto40mm,andsharpedgesandcorners;TwopositionsfortheballDrive30~50mm~35mmx30mmorbelowsteel.Materialsfromonewarehousewasbrokenintotwopanelsafterboothswarehousestores,granularityhasbecome5ramaroundedgesandcornersRuiduohasgreatlyreduced,sotwopositionsChenbanmainlylungmachine,squeezingoutaccumulationandsaltBoard4worn.Feed-MotouchenbanBecauseofthelargerequipmentandmaterialsgranularitysportslarge,sharpedgesandcornersofthesideimpactandslidinghill,thanexpected-combplateswearoutmuchmoreserious.Itpositionspanelsbackoneortwopositionsballssideshocks,butalsotomaterialsthroughhoofoffbywashedlungmachine,andthereforewearisalsomoreseriousifitrequiresboardpositionsbothwearresistancecapacityisnotbroken,weshouldhaveahigheryieldstrengthandhardness,resistancetobending,resistancematerialswashedmaintaincomblinkingwidth,craftsmeetrequirements,itshouldchoosethegoodresiliencehighhardnessofthematerial.EvenwithahammerChenbannotweardifferentpartsKorea,forexample-Chenban,CentralChenbanaffectedbytheimpactofmaterialsandMoqiuserious,especiallytogreetexpectedfacemoreandmorelightisclosetothetaildevice.ReceiverChenbanwhetherladder,prominentcorner,layering,etc.Chenbanwelcomebycuttingsphericalexpected,theimpactofseriousChenbanproductionprocessesindifferentpartsofChinashouldconsidertheresistancetoabrasionresistancetowearandtear,orfromthestructuraldesignofimprovements,suchasMotou-ChenbanwelcomeLiunoodlespluscorner;Awarehousevillageboardwilldoubleladder;Itpositionsboardswornpartsaddthickness,andsoon.InChenbanwearisasystemsengineering,needlesTodifferentconditionsandthestatusofthecorrespondingwear-resistingmaterial.2.4MoqiuthewearandtearfailuresMoqiuballintheMoldovanplaneisthelargestmetalworkexertion.Wearedifferentmaterials,theuseofthesituationindifferentconditionsMoqiuanalysisshowsthewearandtearMoqiulapsefollowingseveralmechanisms:(1)cutandcutwearandtear.Moqiuriseintheupperstage,withrelativelyslidingmaterials,whichwerehardandsharpmaterialsonthesurfaceofadeepertrenchcutbyJingermaterialsisalessbluntthetrench,thesizeofdifferentmaterials,differentsoftandhardacute,resultingintheballbelowthesurfacemineshallow,narrowdifferencescrosscutting.Moqiuslowdowntoacertainpoint,theimpactofmaterials,apartialcutaholeworn.(2)deformationwear.Moqiuandmaterialsrelativeslidingorshock,directcutting,cut,thereareploughsGapdeformationoccurred,andthemetalwaspushedtothenakedeyebelowtheouterside,intheroleofmetaldeformationmaterialsrepeatedlybyacontingencyfatiguecracks,cracksexpand,connecting,formingplowscrapsheet,thesurfacearea.(3)brittlenessspalling.Moqiuaffectedbytheimpactoftheprocessmaterialsbrittlenessof(suchascarbon)shell,brokendownbyhimselffromthesurfaceZhuofilings.(4)fatiguewear.Moqiuinmillswithinthecycleofrise,throw,repeatedlysliding,rollingandimpactofchangesinshockscontactpressurestress,istheroleofastressfatigueinAsiasurfacefatiguecracksformedparalleltoeachother,forminganextensionoffatiguespallingandsurfacelayer.FatiguecracksinAsianextlifeconsistingofamixtureofnuclearmaterialandbrittlenesscangrowinthesurfacelayerandthedynamicssoftenedlayersaskedfornuclear.Whenthecastingsurfaceinmuchofthewrongandmixednuclearexpansionwillleadtomacrofatiguespalling,orapieceofdebriscausedbyballjointsstolenYuan.Nearthesurfaceandleadtomicro-nuclearfatiguespalling,afindinglaminaandspallingpit.破碎粉磨設(shè)備的磨損與耐磨材料的發(fā)展摘要從磨損失效分析入手，對(duì)破碎粉磨系統(tǒng)中易損件的結(jié)構(gòu)形狀、相互匹配關(guān)系、耐磨材料生產(chǎn)工藝、質(zhì)量控制與使用性能等進(jìn)行評(píng)述，并列舉了國(guó)內(nèi)外典型耐磨材質(zhì)的化學(xué)成分覆機(jī)械性能，同時(shí)闡述了破碎粉磨材料的發(fā)展。關(guān)鍵詞：破碎，粉磨，易損件，耐磨材料1引言冶金礦山、建材、火電、化工、煤炭等工業(yè)部門(mén)，需要各種破碎粉磨設(shè)備。這些設(shè)備的易損件受研磨體、襯扳、物料的磨損，每年消耗大量金屬。以水泥工業(yè)為飼，1994年水泥全國(guó)產(chǎn)量4．05億噸。球磨機(jī)襯板類(lèi)、破碎機(jī)類(lèi)損耗金屬約為300～350g／t水泥；研磨介質(zhì)(球、段)為500g／t水泥，這樣1994年僅水泥工業(yè)就消耗襯板類(lèi)金屬12萬(wàn)t，研磨體2o多萬(wàn)t。據(jù)有關(guān)資料統(tǒng)計(jì)，黑色、有色礦山消耗金屬更多，全國(guó)消耗破碎機(jī)、球磨機(jī)襯扳金屬約5o萬(wàn)t，研磨介質(zhì)金屬約130萬(wàn)t，總價(jià)值達(dá)80億元。材料的消耗必然反映到能源消耗上，因此降低金屬材料消耗也是節(jié)約能源的一個(gè)重要方面，具有明顯的經(jīng)濟(jì)效益和社會(huì)效益。同時(shí)因更換易損件而被迫停車(chē)的時(shí)間在水泥行業(yè)約占總停車(chē)時(shí)間的50～55，占因磨損而增加設(shè)備維修工作量的6o～65，因此隨著破碎粉磨設(shè)備工藝技術(shù)的飛速發(fā)展，隨著設(shè)備日趨大型化研制和使用，新型耐磨材料越來(lái)越為人們所重視。2破碎粉磨設(shè)備的磨損破碎粉磨設(shè)備的磨損可分為內(nèi)部因素和外部因素。內(nèi)部因素包括材料的冶金質(zhì)量、化學(xué)成分、金相組織和機(jī)械性能I外部因素包括物料的硬度和韌性，粒度和棱角銳度等等。易損件是否耐用取決于材料的抗沖擊磨損能力，抗疲勞磨損能力，抗顯微切削和犁削的能力。下面對(duì)幾種破碎粉磨設(shè)備主要易損件的磨損進(jìn)行簡(jiǎn)要分析。2.1顫式破辟機(jī)齒板顎式破碎機(jī)齒板的磨損屬于鑿削式磨損。以江蘇常熟采石場(chǎng)使用PZ250~500型顎式破碎機(jī)齒扳為例，齒扳材質(zhì)是經(jīng)水韌處理的標(biāo)準(zhǔn)高錳鋼。在掃描電鏡下觀(guān)察齒扳磨面可以看出，齒扳表面被擠壓成凹凸部分材料，隨后又被磨料推擠形成壓舌磨面，在磨面上可以看到很多磨料尖角短程滑動(dòng)造成的磨痕，并可看到齒板表面有微裂紋，見(jiàn)圖1。經(jīng)過(guò)分析，齒扳磨損的主要原因是磨料相對(duì)齒板短程滑動(dòng)、切削金屬造成磨屑和磨料反復(fù)擠壓引起齒扳材料多次變形，導(dǎo)致金屬材料疲勞脫落，磨損失教過(guò)程是：(1)物料多次反復(fù)擠壓鑿削齒扳，在齒扳區(qū)表層，或在擠壓金屬的突出部分根部形成微裂紋，此微裂紋不斷擴(kuò)展到相連，造成表面金屬材料脫落，形成磨屑。(2)物科反復(fù)擠壓，造成齒扳金屬材料被局部壓裂或翻起，其碎裂或翻起部分又隨著擠壓撞擊的物料一起脫落形成磨屑(3)物料相對(duì)齒板短程滑動(dòng)，切削齒板形成磨屑。因此從耐磨材料上控制齒板磨損主要是硬度和韌性。材料硬，物料擠壓深度淺，材料變形小，物料對(duì)材料短程滑動(dòng)的切削量也小材料韌性好，抵抗斷裂能力強(qiáng)，可消除擠壓撞擊過(guò)程中脆性斷裂，提高抗疲勞變形開(kāi)裂能力。顎式破碎機(jī)的大小規(guī)格不同，進(jìn)料粒度、銳度不同，對(duì)齒板的擠壓、撞擊力不同，大中型擠壓力大，除考慮材料的抗擠壓力和抗滑動(dòng)切削外，還應(yīng)考慮受撞擊時(shí)的沖擊力及彎曲應(yīng)力因此大型齒板選材應(yīng)選用韌性高、綜合性能好的材質(zhì)從上述磨損失效分析可知，對(duì)于齒板材料應(yīng)選擇硬度高的材質(zhì)以抵抗擠壓、顯微切削失效，選擇足夠韌性柏材質(zhì)以抵抗鑿削撞擊疲勞失效。同時(shí)從齒板結(jié)構(gòu)上進(jìn)行改進(jìn)，以減少物料與齒板的相對(duì)滑動(dòng)，這不僅對(duì)提高生產(chǎn)率有益，而且對(duì)提高材料的使用壽命也有益。2.2錘式破碎機(jī)錘頭不同規(guī)格的錘式破碎機(jī)，錘頭形狀大小也各不相同，一般認(rèn)為90～125kg的錘頭為大型，25kg以下為小型，其余為中型。大中水泥廠(chǎng)一般使用25～50kg錘頭。由于錘頭大小不同，使用工況條件不同，它的磨損失效也各不相同。錘頭的磨損方式，以沖擊鑿削為主，伴隨有沖刷顯微切削磨損。其磨損形貌為沖擊坑和切削犁溝。由于錘頭的主要磨損方式為沖擊，所以人們習(xí)慣于選擇高錳鋼做錘頭材質(zhì)。(1)12kg以下錘頭由于其沖韌小，不能充分發(fā)揮高錳鋼的加工硬化作用，因此耐磨性很不理想，如破碎長(zhǎng)石、劣質(zhì)煤和高爐礦渣等物料，錘頭有的用幾天甚至幾個(gè)班即失效。有人把玻璃廠(chǎng)用5．8kg錘頭和水泥廠(chǎng)用11．5kg錘頭進(jìn)行磨損后殘?bào)w失效分析，結(jié)果表明兩類(lèi)錘頭加工硬化效果都很差，表面硬化曲線(xiàn)如圖2所示。小錘頭的磨損過(guò)程是一方面物料小能量沖擊錘頭，金屬表面產(chǎn)生塑性變形和徽裂紋。在反復(fù)多次塑變情況下裂紋擴(kuò)展，金屬受擠壓形成碎片脫落，導(dǎo)致沖擊磨損；另一方面物料刺入材料表面，在一定法向力與切向力作用下，對(duì)材料表層金屬產(chǎn)生顯微切削、沖刷，使金屬表面磨損，但由于沖擊力大，高錳鋼不足以被加工硬化。所以應(yīng)選擇有一定韌性，以硬度高為主導(dǎo)的材料才能大幅度提高使用壽命。(2)50kg級(jí)錘頭由于其沖擊力大，采用高韌性的高錳鋼材質(zhì)，其加工硬化性能得到一定發(fā)揮，錘頭以磨損、沖擊、鑿削為主，伴隨沖刷顯微切削磨損，磨損的微觀(guān)形貌表現(xiàn)為沖擊坑和切削犁溝。但是如果物料工況條件不同，同樣是高錳鋼錘頭使用情況也相差很大。如同樣是陜西延河水泥機(jī)械廠(chǎng)生產(chǎn)的12P50kg級(jí)高錳鋼錘頭，在永登水泥廠(chǎng)僅應(yīng)用2～3個(gè)月即失效；在耀縣水泥廠(chǎng)可用8～11個(gè)月。電鏡觀(guān)察永登水泥廠(chǎng)錘頭在磨損面上主要是切削犁溝，有沖擊坑存在，說(shuō)明其磨損失效是以切削機(jī)理為主，向時(shí)伴隨有撞擊磨損。分析原因是該廠(chǎng)石灰石物料中含泥量大，粒度小，使沖擊負(fù)荷減小，高錳鋼加工硬度不明顯，同時(shí)物料中