錘式破碎機的設計【含4張CAD圖紙+文檔】
錘式破碎機的設計【含4張CAD圖紙+文檔】,含4張CAD圖紙+文檔,破碎,設計,cad,圖紙,文檔
學生姓名： 學號：
學 院： 專業(yè)：
任務起止時間：2013年2月25日至2013年6月21日
畢業(yè)設計（論文）題目：錘式破碎機的設計
畢業(yè)設計工作內(nèi)容：國家自然科學基金項目
設計內(nèi)容和要求：
設計圖紙要求裝配圖、零件圖等（全部采用計算機繪圖）圖量折合A0圖不少于1.5張。設計計算說明書一份，要求：語言通順、論據(jù)充分、結(jié)論正確，并含有中、英文摘要和外文資料翻譯。
1. 熟悉課題、調(diào)研收集資料、方案設計 2月25日~3月17日
撰寫開題報告
2 錘式破碎機結(jié)構(gòu)設計
（總裝圖及重要零件圖合計1.5張） 3月18日~4月21日
3. CAD畫出零件圖 4月22日~5月19日
4. 設計說明書1份（外文翻譯，至少5000字符） 5月20日~6月16日
5. 答辯準備及答辯 6月17日~6月25日
資料：
1.機械制造工藝設計手冊 哈爾濱工業(yè)大學出版社 1992
2. 機械設計手冊 上冊 化學工業(yè)出版社
3.王三民,諸文俊.機械原理與設計[M].機械工業(yè)出版社,2001.
指導教師意見：
提前一周交畢業(yè)設計。
簽名：
2013年 2月 25日
系主任意見：
簽名：
年 月 日
畢業(yè)設計（論文）任務書
教務處制表
畢業(yè)設計（論文）開題報告
一、課題題目及來源：
課題題目：錘式破碎機的設計
課題來源：國家自然科學基金項目
二、課題研究的意義和國內(nèi)外研究現(xiàn)狀：
2．1課題研究的意義
料的破碎是許多行業(yè)產(chǎn)品生產(chǎn)中不可缺少的工藝過程。由于物料的物理性質(zhì)和結(jié)構(gòu)差異很大,為適應各種物料的要求,破碎機的品種也是五花八門的。就金屬礦選礦而言,破碎是選礦廠的首道工序,為了分離有用礦物,不但分為粗碎、中碎、細碎,而且還要磨礦。因為磨礦是選礦廠的耗能大戶,為了節(jié)能和提高生產(chǎn)效率,所以提出了“多碎少磨”的技術原則。這使破碎機向細碎、粉碎和高效節(jié)能方向發(fā)展。另外隨著工業(yè)自動化的發(fā)展,破碎機也向自動化方向邁進。隨著開采規(guī)模的擴大,破碎機也在向大型化發(fā)展,如粗碎旋回破碎機的處理能力已達6000t/h。至于新原理和新方式的破碎尚在研究試驗中,暫時還不能用于生產(chǎn)。
??? 對粗碎而言,目前還沒有研制出更新的設備以取代傳統(tǒng)的顎式破碎機和旋回式破碎機,主要是利用現(xiàn)代技術,予以改進、完善和提高耐磨性,達到節(jié)能、高效、長壽的目的。細碎方面新機型更多些?？偟膩砜?值得提出的有:顎式破碎機、圓錐破碎機、沖擊式破碎機和輥壓機
2．2國內(nèi)研究現(xiàn)狀
根據(jù)參考文獻[1]知我國胡景坤和徐小荷研究顆粒的粉碎時得出結(jié)論，靜壓粉碎效率為100%，單次沖擊效率在35%～40％左右。為了節(jié)約能量，提高粉碎效率，應多用靜壓粉碎，少用沖擊粉碎。
在各種金屬、非金屬、化工礦物原料及建筑材料的加工過程中，粉碎作業(yè)要消耗巨大的能量，而且又是個低效作業(yè)。物料粉碎過程中，由于作業(yè)中產(chǎn)生發(fā)聲、發(fā)熱、振動和摩擦等作用，使能源大量消耗。因而多年來界內(nèi)人士一直在研究如何達到節(jié)能、高效地完成破碎過程。
目前破碎理論、工藝和設備的研究主要著重于：(1)研究在破碎中節(jié)能、高效的理論，也力求找出新 理論突破人們已熟知的破碎三大理論；(2)研究新的非機械力的高能或多力場聯(lián)合作用的破碎設備，目前還沒見有工業(yè)化的設備，只是研究階段；(3)改進現(xiàn)有設備，這方面經(jīng)常是根據(jù)用戶自己需要來進行，而不見市場上大規(guī)模生產(chǎn)或研制新設備。
2．3國外研究現(xiàn)狀
物料破碎是一個歷史悠久的話題。早在20世紀50年代艾利斯時，－查爾默斯公司就開始大規(guī)模研究破碎工作，60年代得出具有重大意義的結(jié)論。隨著研究的深入，人們熟知了高功率的破碎作業(yè)，可以用來改善能源效率和降低生產(chǎn)成本。B． H．Bergstrom在研究單顆粒破碎時發(fā)現(xiàn)，在空氣中一次破碎的碎片撞擊金屬板時明顯地產(chǎn)生二次破碎，一次破碎的碎片具有的動能占全部破碎能量的45％。如能充分利用二次破碎能量，則可提高破碎效率。也有人指出，較小的持續(xù)負荷比短時間的強大沖擊更有希望破碎物料。目前“料層粉碎的理論”已為粉碎界的公認，根據(jù)料層粉碎理論研制的新設備有美國諾德伯格公司的旋盤圓錐破碎機、俄 羅斯的慣性圓錐破碎機等。
三．課題研究的主要內(nèi)容和方法，研究過程中的主要問題和解決辦法：
3．1．1課題研究的主要內(nèi)容
1．了解錘式破碎機的基本結(jié)構(gòu)和原理
2．錘式破碎機總體設計方案
3．錘式破碎機的機構(gòu)結(jié)構(gòu)設計
3．1．2課題研究的主要方法
1. 學習破碎機的結(jié)構(gòu)型式、運動學等知識。查閱資料，了解穿刺機構(gòu)的最新研究成果
2.通過計算，完成必要的剛度分配計算
3..在互聯(lián)網(wǎng)上查找有關錘式破碎機的設計方面知識，以及動力設備知識，并設計相關方案；
4. 用CAD等設計軟件完成錘式破碎機的總體設計
3．2研究過程中的主要問題和解決方法
3.2.1主要問題
1因此在設計過程中主要考慮主軸、錘頭、軸承的受力情況，從而設計合適的主軸。
的結(jié)構(gòu)設計
合適的主軸 因此在設計過程中主要考慮主軸、錘頭、軸承的受力情況，從而設計合適的主軸。
2.機械傳動機構(gòu)的設計
如何設計內(nèi)部的動力傳動等
3.總體制圖
對錘式破碎機的各個模塊零件進行二維制圖
3.2.2解決方法
1.查閱錘式破碎機相關的文獻并學習相關知識；
2.利用網(wǎng)絡檢索相關信息；
3.請教指導教師，最終解決所遇到的難題。從而順利完成此次畢業(yè)設計所規(guī)定的任務。
四．課題研究所需的參考文獻
1. 李洪.機械設計與制造工藝, 沈陽遼寧科學技術出版社，1999
2. 于鵬軍.錘式破碎機錘頭重量的確定，礦山機械，2002
3. 唐敬麟.破碎與篩分機械設計選用手冊.化學工業(yè)出版，2000
4. 周恩浦.錘式破碎機錘頭的動力學及錘頭運動的穩(wěn)定性.中南礦冶學院學報，1983：28～30
5. [德]J.Lewinski.單塊礦粒對錘式破碎機錘頭的沖擊作用的分析.選礦機械，1987年：42～44
6. Sutton G P.The machine tool task forch. Bal Habour Hotel,1980
7. Mou J,Liu C R.An error correction method for CNC machine tools using reference parts.transactions of NAMRE/SME,1994
8．Chang W C,Van Y T.Researching Design Trens for the Redesign of Product From Design Studies 2003.24(2):173_180
9．Michael Korneli, Contributing Writer. Designing progressive dies.2001
10. 周恩浦.礦山機械.冶金工業(yè)出版社，1978
指導教師審查意見：
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錘式破碎機的設計
摘要
錘式破碎機大量應用于水泥廠、電廠等各個部門，所以，它的設計有著廣泛的前景和豐富的可借鑒的經(jīng)驗。其設計的實質(zhì)是，在完成總體的設計方案以后，就指各個主要零部件的設計、安裝、定位等問題，并對個別零件進行強度校核和試驗。并在相關專題中，對錘頭的壽命延長進行比較詳細的分析。在各個零部件的設計中，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。在強度的校核是，要運用的相關公式，進行危險部位的分析、查表、作圖和計算等。并隨后對整體進行安裝、工作過程以及工作后的各方面的檢查，同時兼顧到維修、保險裝置等方面的問題，最后對兩個主要工作零件的加工精度、公差選擇進行分析，以保證破碎機最終設計的經(jīng)濟性和可靠性。
關鍵詞：錘式破碎機；錘頭；強度；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
不要刪除行尾的分節(jié)符，此行不會被打印
- 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 國內(nèi)外現(xiàn)狀 1
1.3.1 國內(nèi)發(fā)展情況 1
1.3.2 國外發(fā)展情況 2
第2章 原理及其設計方案的確定 3
2.1 破碎機的結(jié)構(gòu)及原理 3
2.1.1 破碎原理 3
2.1.2 破碎機的主要結(jié)構(gòu) 3
2.2 設計方案 4
2.3 本章小結(jié) 4
第3章 錘式破碎機的電動機功率的計算和選擇 5
3.1破碎機電動機功率的計算 5
3.1.1 綜合各種因素計算功率 5
3.1.2 根據(jù)生產(chǎn)實踐以及引用經(jīng)驗公式計算電動機功率 6
3.2 電動機型號的選擇 7
3.3 本章小結(jié) 7
第4章 錘式破碎機的主要機構(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)子軸的設計 9
4.3.1轉(zhuǎn)子軸尺寸設計 9
4.3.2轉(zhuǎn)子軸的校核 11
4.4錘頭參數(shù)的設計 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帶傳動部分的設計 16
4.5.1 設計步驟和方法 16
4.5.2 帶輪的設計 18
4.6圓盤的設計 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 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.
談單段錘式破碎機錘頭的選擇
摘 要
重點介紹新一代錘式破碎機錘頭的設計、制造及材質(zhì)選擇。
關鍵詞 破碎機錘頭 設計 制造 材質(zhì)
新一代單段沖擊式錘式破碎機在西歐水泥工業(yè)中出現(xiàn)后,至今已二十多年,廿多年來,它從工藝結(jié)構(gòu)的設計,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備,它已在國外許多工業(yè)發(fā)達的水泥廠及石灰石礦山車間普遍推廣應用。并且以一級破碎的工藝,取代了長期襲用的二級或三級破碎工藝,達到了較好的效果。一級破碎工藝的出現(xiàn),簡化了破碎工藝,在新建或改造石灰石礦山方面,減少了破碎輸送、收塵等設備及廠房、中間倉儲料斗的筑投入,節(jié)約工程建設總投資,而且在生產(chǎn)中還節(jié)約了大量的電能,減少了設備的操作維修人員,取得了較好的技術經(jīng)濟效果。這種一級破碎工藝,八十年代進入我國后,已在我國大中型水泥廠建設和改造中普及應用。
這種新式破碎機,是在舊的破碎機的基礎上,從結(jié)構(gòu),主要零件的設計、制造,材料選用上不斷改進發(fā)展而成的,比如北京重型機械廠,引進德國O&K公司的MB型錘式破碎機,它的破碎腔作了特殊設計,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。如在福建龍巖水泥廠的兩次載荷試車運轉(zhuǎn)中,先后把一塊厚度35mm,重達38公斤的環(huán)狀襯板及一塊重6公斤的鐵塊反彈出來,更加典型的是在湖北華新水泥廠,將一個4立方米電鏟的鏟牙安全的反彈出,機器沒有受到任何傷害。它的主要工作零件——錘頭,其工況條件的嚴酷性,是老式錘式破碎機所無法比擬的,而其可靠性和使用壽命,也是一般老式錘式破碎機所不具備的,已成為這一破碎機的關鍵。下面對這類破碎機錘頭作一些扼要介紹:
1 錘頭的選定
德國的奧倫期坦-科佩爾公司(O&K)的MAMMUT(簡稱MB型) 破碎機,丹麥史密斯公司(FLS)EV破碎機;德國洪堡公司(KHD)的HES和HDS型,使用以上破碎機,都十分注重石灰石的化學成分,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,所以錘頭的設計與制造必須考慮其在破碎腔中的工作情況。通常礦石進入破碎腔后,都以一定的落差受到高速運轉(zhuǎn)錘頭的強列沖擊。新型的破碎機,不但其沖擊力強,而且使物料在錘架和錘頭的運動中,獲得動能,高速沖擊破機腔內(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,排出機體。這些錘頭工作的線速度,一般取30～33米/秒,丹麥史密斯公司的EV型錘式破碎機錘頭的線速度最高曾取39米/秒,每個錘頭參與打擊的頻率是每秒4～6次。
3 錘式破碎機錘頭失效的分析
根據(jù)上述情況,新型的錘式破碎機錘頭,在工作時本身承受著離心力,作用于礦石的沖擊、銑削,又承受著礦石的強烈的反作用力的沖擊,還有錘孔與錘軸之間接觸的磨擦應力和拉伸力,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)的選擇不當及制造工藝的缺陷,使錘頭本身的強度及塑性不足,產(chǎn)生應力集中,或使用不當?shù)纫蛩卦斐伞Ｋ愿哔|(zhì)量的錘頭,必須具有堅硬的表面或良好的硬化效果,還要具有足夠的內(nèi)部強度和良好的塑性力學性能,才能在破碎腔內(nèi)適應反復沖擊破碎的工作,實現(xiàn)其磨損小,效率高的目的。
4 錘頭的材質(zhì)及制造
當今錘式破碎機錘頭使用的材質(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,它是一種無磁性奧氏體鋼,是典型的高強度耐磨鋼,具有高的韌性,抗拉強度和延伸率,它是在高錳鋼的基礎上,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損于抗拉強度和延伸率,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準,通過自己的工藝技術和內(nèi)控指標,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力的沖擊,而且還要耐磨蝕,當石灰石品位屬于中等硬度,甚至偏軟時,一般高錳鉻鋼的冷作硬化效果是不明顯的,德國O&K公司MAMMUT破碎機和洪堡(K.H.P)HES破碎機均選擇了合金鋼鍛造的錘頭,北京重型機器廠引進德國O&K公司的MAMMUT破碎機許可證技術后,其生產(chǎn)MB系列錘式破碎機錘頭,根據(jù)礦石條件也選用鍛 造材質(zhì),其工藝過程為:
精煉合金鋼 注成鋼錠—→鍛造開坯—→模鍛成型—→調(diào)質(zhì)處理—→加工錘孔等—→錘頭打擊區(qū)熱處理—→無損探傷。在鋼水的冶煉和注錠過程中,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,在水壓機上開坯拔長,然后在16噸的高速錘或10噸模鍛機上鍛成規(guī)定的幾何形狀。錘頭的調(diào)質(zhì)熱處理十分關鍵,要求其整體抗拉強度在850MPa以上,而且要求有相當?shù)捻g性和塑性。在錘孔加工后,對錘端打擊區(qū)進行表面淬火,不僅要求其表面硬度達HB410～460,而且其內(nèi)部的硬度梯度,要求嚴格控制在公差帶內(nèi),因此每批錘頭除選一件在錘孔附近取試件進行綜合機械測試外,還要任選一件沿錘頭對稱中心剖開,按規(guī)定的距表面距離,分等線距地檢測其硬度,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)量萬無一失。這些鍛件的材質(zhì),德國O&K公司選用450鋼,洪堡(K.H.D)則選用30CrMo9V,美國ES-CO公司,選用12S。以上三種牌號材料,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,為此比利時的馬格托(MOgoffeox)公司,根據(jù)其兩個方面受力不同要求不同,生產(chǎn)一種復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,它們在材料的冶煉和熱處理方面都要求十分嚴格,高鉻鑄鐵部分經(jīng)過高溫淬火、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),它的化學成分及鑄造如示意圖
表2復合材料錘頭化學成分表
美國的ESCO公司,研制了一種組合式的破碎機錘頭如圖示,其特點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)介紹當錘柄磨損到報廢時,它可能已更換了10～30付錘頭,每次更換錘頭時,真正扔掉的金屬,僅占整個錘頭重量的25%～35%,可見是較經(jīng)濟的。
圖1 復合材料錘頭
圖2 可快速更換的組合錘頭
4.4 磨損后的堆焊修復錘頭
對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。高錳鋼及高錳鉻鋼,由于熱效應對其金屬組織的影響不易控制,因此堆焊難以達到令人 滿意的效果。德國O&K公司,對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、加強層三層進行焊復,每層所用的堆焊材料是不同的,在實施堆焊之前,錘頭焊接面必須清洗干凈并進行予熱,在實施堆焊過程中為體溫度應控制在350℃～400℃以內(nèi),焊后應用保溫熱材料緩冷,防止因冷卻太快而產(chǎn)生裂紋,這種堆焊可不拆卸錘頭,在機內(nèi)進行,其三種堆焊材料的成分及堆焊修復示意圖如下:
表2 堆焊材料的化學成分
圖3 錘頭的堆焊修復
5 錘頭的合理選型
在設計一臺石灰石破碎機時,設計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 關于錘頭優(yōu)劣的判定
錘式破碎機錘頭的優(yōu)劣與否,通常是通過某一粒度要求的處理量及錘頭的磨耗來判定,其判定的兩種數(shù)值如下
式中G——單個錘頭的重量(kg)
n——破碎機安裝錘頭數(shù)量
K——每個錘頭允許磨損部分占整個錘頭的重量比(%)
T——一套錘頭的石灰石處理量(t)
W——磨耗比(克/噸)
每個錘頭允許的磨損量,一般為12～15%不得超過17%,因為錘頭損失過多,使錘頭沖擊板及篦條之間的間隙過大,將影響產(chǎn)品粒度,對于用戶準備堆焊修復的鍛造錘頭,則應在其磨損部分小于10%之前進行修復。
冀中水泥廠,曾引進德國O&K公司的7090型MAMMUT破碎機,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,可這臺破碎機原配的一套高錳鉻鋼錘頭處理了150多萬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。如我國南方某水泥廠引進的同類破碎機所用的此種錘頭,僅處理了不到30萬噸石灰石就磨損報廢了。
高鉻鑄鐵的復合錘頭,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,但還沒有見到有關經(jīng)濟效益的報導。
大多數(shù)石灰石的擠壓強度小于140MPa,所以使用高錳類鑄鋼時,不易充分得到高錳鋼在冷作硬化時應取得的硬度而早期磨損,而合金鋼鍛造錘頭,因其具有強韌的整體和堅硬的沖擊表面,較適于破碎中等硬度的石灰石,北京重型機械廠在引進德國O&K公司的制造技術后生產(chǎn)的這種鍛造錘頭,在華新水泥廠MB破碎機的使用中,經(jīng)過考驗,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)的機械性能和質(zhì)量,而且用戶也要重視錘頭的科學選型,做到“因材施錘”以合理科學的管理,全面地提高錘頭的使用壽命。
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