A method for preparing a high-wear-resistant and strong crusher blade and a blade obtained by the method

Abstract

The application relates to the technical field of material crushing, in particular to a preparation method of a high-wear-resistance and high-toughness crusher blade and the obtained blade, and the preparation method comprises the following steps: blanking a steel billet into a steel block and forging the steel block into a circular ring, rough machining, quenching and tempering heat treatment and fine machining are performed on the upper and lower surfaces of the circular ring, so that the upper and lower surfaces of the circular ring are flat and have a hardness of HRC 28-32; an induction coil is prepared, the upper and lower surfaces of the circular ring are subjected to induction quenching treatment, so that the surface hardness of the circular ring reaches HRC 58-62; a plurality of teeth are machined in the circumferential direction of the circular ring to obtain a preform; a profiled coil is prepared, and the teeth are subjected to induction quenching treatment, so that the hardness of the side surfaces of the teeth reaches HRC 58-62; the preform is subjected to grinding and a spline hole or a hexagonal hole is machined to obtain the high-wear-resistance and high-toughness crusher blade; the application can obtain the crusher blade which has high surface hardness, high wear resistance, toughness in the core and does not break and fail when crushing hard objects.

Description

Technical Field

[0001] This invention relates to the field of material crushing technology, and in particular to a method for preparing high wear-resistant and tough crusher blades and the blades obtained therefrom. Background Technology

[0002] Crusher blades are the core working components of a crusher. Crushers primarily rely on these blades to cut minerals and metals into fragments of predetermined sizes. During operation, crusher blades are subjected to alternating cyclic loads and bending fatigue loads, making them prone to fatigue fracture. Therefore, crusher blades are highly susceptible to wear or breakage during the crushing process. Current domestic crusher blade production methods mainly use alloy steel, such as 42CrMo, undergoing integral quenching heat treatment. Due to the high core hardness and poor toughness, this easily leads to integral fracture. In contrast, many foreign manufacturers cut wear-resistant plates to produce crusher blades. However, since wear-resistant plates are currently available, they are only available in 20mm, 30mm, 40mm, and 50mm diameters. Fixed thicknesses like 60mm are unsuitable for producing blades of higher thicknesses, such as 100mm. If a different thickness is desired, such as 52mm, custom-made wear-resistant plates are required, or a 60mm plate needs to be machined to 52mm, resulting in significant machining work and high costs. Regarding material selection, HRC50 wear-resistant plates have low hardness, leading to short blade lifespans. HRC60 plates, with their high core hardness and poor toughness, are prone to causing blade breakage. Furthermore, wear-resistant plates are typically square; machining them into round crusher blades results in waste of raw materials at the four corners.

[0003] Therefore, in order to address the above problems, the present invention urgently needs to provide a method for preparing high wear-resistant and tough crusher blades and the blades obtained therefrom. Summary of the Invention

[0004] The purpose of this invention is to provide a method for preparing high wear-resistant and tough crusher blades and the resulting blades. By using forging and induction heating quenching design, the invention solves the problems of easy breakage, wear and material waste caused by the uniform overall hardness in the prior art. This allows for the customization of crusher blades of various thicknesses and tooth shapes, while the manufactured crusher blades meet the requirements of high surface hardness and core toughness.

[0005] This invention provides a method for preparing high wear-resistant and tough crusher blades, comprising the following steps: 1) Cut the steel billet into multiple steel blocks, forge the steel blocks into rings, and perform rough machining, tempering heat treatment and fine machining on the upper and lower surfaces of the rings in sequence, so that the upper and lower surfaces of the rings are flat and the hardness of the rings is HRC28-32. 2) Prepare an induction coil and use the induction coil to perform induction hardening on the upper and lower surfaces of the ring so that the hardness of the upper and lower surfaces of the ring reaches HRC58-62. 3) Multiple teeth spaced apart are machined on the circumference of the ring to obtain a preform; 4) Prepare a contoured coil, cover the side surface of each tooth with the contoured coil in sequence and heat it with electricity so that the hardness of the side surface of each tooth reaches HRC58-62; wherein, the shape of the contoured coil matches the shape of the side surface of a single tooth and covers the entire tooth. 5) Grind the upper and lower surfaces of the preform and machine a splined hole or hexagonal hole for mounting the drive shaft at the center of the preform to obtain a high wear-resistant and tough crusher blade.

[0006] Preferably, the induction coil is in the shape of a straight line, wherein the length of the induction coil is the same as the radius of the ring.

[0007] Preferably, in step 2), the depth of induction hardening of the ring is 3-5 mm.

[0008] Preferably, the ring comprises a first ring and a second ring from the inside out, wherein the width of the first ring is 25mm; in step 2), the range of the ring subjected to induction hardening is the second ring.

[0009] Preferably, induction hardening includes energizing and heating an induction coil and placing it close to the upper and lower surfaces of the ring, such that one end of the induction coil contacts the outer surface of the ring and the induction coil is parallel to one of the radii of the ring, rotating the ring around the center or rotating the induction coil around the ring, such that the heating range of the induction coil covers the upper and lower surfaces of the ring.

[0010] Preferably, in step 2), the induction hardening of the ring is medium-frequency hardening with a frequency of 1-10 kHz.

[0011] Preferably, the billet is made of 40CrNiMoA or 42CrMo.

[0012] Preferably, in step 5), the processing method is wire cutting or milling.

[0013] Preferably, in step 2), after machining, ultrasonic testing is used to ensure that there are no defects inside the ring.

[0014] The present invention also provides a high wear-resistant and tough crusher blade obtained based on the high wear-resistant and tough crusher blade preparation method described above, comprising an annular body of uniform thickness, a plurality of teeth of uniform shape distributed circumferentially on the side surface of the body, and a spline hole or hexagonal hole penetrating the body provided at the center of the upper and lower surfaces of the body. The main body comprises, from the inside out, a third ring and a fourth ring. The width of the third ring is 25 mm, and its hardness is HRC28-32. The fourth ring, along its thickness direction from top to bottom, comprises an upper surface layer, a central layer, and a lower surface layer. The thickness of the upper and lower surface layers is 5 mm, and their hardness is HRC28-62. The hardness of the central layer is HRC28-32. The hardness of each tooth is HRC58-62.

[0015] The present invention provides a method for preparing high wear-resistant and tough crusher blades, and the resulting blades have the following advantages compared with the prior art: This invention provides a method for preparing high wear-resistant and tough crusher blades and the resulting blades. The method can process crusher blades of arbitrary thickness and shape, while ensuring that the core hardness is HRC28-32, and that the hardness of both sides and the outer surface of the teeth reaches HRC58-62. This results in crusher blades with high surface hardness and wear resistance, as well as core toughness, preventing fracture failure when crushing hard materials. The invention employs induction hardening, which offers high thermal efficiency, short heating time, minimal workpiece deformation, no oxidation or decarburization, and facilitates localized heat treatment, enabling clean production. This results in workpieces with higher surface hardness and residual compressive stress, exhibiting superior strength and fatigue resistance under torsional loads, and the hardened layer depth is easily controlled. Furthermore, the high wear-resistant and tough crusher blades of this invention utilize multiple induction hardening processes with a single contour coil, rather than using a contour coil with an integral tooth shape, resulting in lower cost, lower power requirements for induction heating equipment, and easier implementation. Attached Figure Description

[0016] To more clearly illustrate the specific embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the specific embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0017] Figure 1 This is a flowchart of the method for preparing high wear-resistant and tough crusher blades as described in this invention; Figure 2 This is a schematic diagram (top view) of the structure of the ring described in step 1) of this invention; Figure 3 This is a schematic diagram of the induction hardening described in step 2) of this invention; Figure 4 This is a schematic diagram of the contour induction hardening described in step 4) of the present invention; Figure 5 This is a schematic diagram (top view) of the structure of the high wear-resistant and tough crusher blade described in this invention. Figure 6 This is a schematic diagram (three-dimensional view) of the high wear-resistant and tough crusher blade described in this invention.

[0018] Explanation of reference numerals in the attached figures: 1. Tooth; 2. First ring; 3. Second ring; 4. Main body; 5. Third ring; 6. Fourth ring; 7. Spline hole or hexagonal hole; 8. Induction coil; 9. Contouring coil. Detailed Implementation

[0019] The technical solution of the present invention will be clearly and completely described below. Obviously, the described embodiments are only some embodiments of the present invention, not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0020] In the description of this invention, it should be noted that the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing the invention and for simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the invention. Furthermore, the terms "first," "second," and "third" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0021] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0022] like Figure 1 As shown in the figure, this embodiment provides a method for preparing high wear-resistant and tough crusher blades, including the following steps: 1) such as Figure 2 As shown, the steel billet is cut into multiple steel blocks and the steel blocks are forged into rings. The upper and lower surfaces of the rings are then subjected to rough machining, tempering heat treatment, and finish machining in sequence, so that the upper and lower surfaces of the rings are flat and the rings have a hardness of HRC28-32. 2) such as Figure 3As shown, an induction coil 8 is prepared, and the induction coil 8 is used to perform induction hardening on the upper and lower surfaces of the ring, so that the hardness of the upper and lower surfaces of the ring reaches HRC58-62. 3) such as Figure 4 As shown, multiple teeth 1 spaced apart are machined in the circumference of the ring to obtain a preform; 4) such as Figure 4 As shown, a contouring coil 9 is prepared, and the contouring coil 9 is sequentially covered on the side surface of each tooth 1 and heated by electricity so that the hardness of the side surface of each tooth 1 reaches HRC58-62; wherein, the shape of the contouring coil 9 matches the shape of the side surface of a single tooth 1 and covers the entire tooth 1. 5) such as Figure 5 As shown, the upper and lower surfaces of the preform are ground, and a spline hole or hexagonal hole 7 for mounting the drive shaft is machined at the center of the preform to obtain a high wear-resistant and tough crusher blade.

[0023] This invention provides a method for preparing high wear-resistant and tough crusher blades, capable of processing crusher blades of arbitrary thickness and shape. It ensures that, while maintaining a core hardness of HRC28-32, the hardness of both sides and the outer surface of the teeth reaches approximately HRC60. This results in crusher blades with not only high surface hardness and wear resistance but also core toughness, preventing fracture failure when crushing hard materials. The invention employs induction hardening, which offers high thermal efficiency, short heating time, minimal workpiece deformation, no oxidation or decarburization, and facilitates localized heat treatment, enabling clean production. This results in workpieces with higher surface hardness and residual compressive stress, exhibiting superior strength and fatigue resistance under torsional loads, and the hardened layer depth is easily controlled. Furthermore, the crusher blade teeth of this invention are induction hardened multiple times using a single contour coil, rather than using a contour coil with an integral tooth shape, resulting in lower cost, lower power requirements for induction heating equipment, and easier implementation.

[0024] In this embodiment, in step 1), the upper and lower surfaces of the ring are first rough-machined to ensure that the upper and lower surfaces of the ring are flat and smooth; after quenching and tempering heat treatment, the upper and lower surfaces of the ring are then fine-machined to handle the deformation after quenching and tempering heat treatment; in step 5), grinding is used to eliminate the traces of quenching treatment and ensure the parallelism of the upper and lower surfaces of the preform; and when machining spline holes or hexagonal holes 7, it is necessary to ensure that the upper and lower surfaces of the preform are perpendicular to the axis of the hole.

[0025] In this invention, the teeth of the crusher blade are induction hardened multiple times using a contour coil 9 that matches the shape of a single tooth 1, instead of using a contour coil that matches the overall tooth shape. This method is less expensive, requires less power from the induction heating equipment, and is easier to implement.

[0026] like Figure 3As shown, the induction coil 8 is in the shape of a straight line, wherein the length of the induction coil 8 is the same as the radius of the ring.

[0027] In this embodiment, in step 2), the depth of induction hardening of the ring is 3-5 mm.

[0028] like Figure 2 As shown, the ring consists of a first ring 2 and a second ring 3 from the inside out, wherein the width of the first ring 2 is 25mm; in step 2), the range of the ring subjected to induction hardening is the second ring 3.

[0029] In this embodiment, in step 2), induction hardening includes energizing and heating the induction coil 8 and placing it close to the upper and lower surfaces of the ring, such that one end of the induction coil 8 contacts the outer surface of the ring and the induction coil 8 is parallel to one of the radii of the ring. The ring is then rotated around its center or the induction coil 8 is rotated around the ring, such that the heating range of the induction coil 8 covers the upper and lower surfaces of the ring.

[0030] In this embodiment, in step 2), the induction hardening of the ring is medium-frequency hardening with a frequency of 1-10 kHz.

[0031] In this embodiment, the billet is made of 40CrNiMoA or 42CrMo.

[0032] In this embodiment, in step 5), the processing method is wire cutting or milling.

[0033] In this embodiment, in step 2), after machining, ultrasonic testing is used to ensure that there are no defects inside the ring.

[0034] like Figure 5 As shown, this embodiment also provides a high wear-resistant and tough crusher blade obtained based on the high wear-resistant and tough crusher blade preparation method described above, including an annular body 4 with uniform thickness, a plurality of teeth 1 of uniform shape distributed circumferentially on the side surface of the body 4, and a spline hole or hexagonal hole 7 penetrating the body 4 at the center of the upper and lower surfaces of the body 4. The main body 4 includes a third ring 5 and a fourth ring 6 from the inside out. The width of the third ring 5 is 25mm and the hardness of the third ring 5 is HRC28-32. The fourth ring 6 includes an upper surface layer, a central layer and a lower surface layer from top to bottom along the thickness direction. The thickness of the upper surface layer and the lower surface layer is 5mm and the hardness of the upper surface layer and the lower surface layer is HRC28-62. The hardness of the central layer is HRC28-32. The hardness of each tooth 1 is HRC58-62.

[0035] This invention provides a high wear-resistant and tough crusher blade that ensures a core hardness of HRC28-32 while maintaining a hardness of approximately HRC60 on both sides and the outer surface of the tooth. This results in a crusher blade with not only high surface hardness and wear resistance but also core toughness, preventing breakage when crushing hard materials. Furthermore, the high wear-resistant and tough crusher blade of this invention uses a single contour coil for multiple induction hardening of the teeth, rather than using a contour coil with an integral tooth shape. This reduces costs, lowers the power requirements for induction heating equipment, and makes it easier to implement.

[0036] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. A method for preparing high wear-resistant and tough crusher blades, characterized in that: Includes the following steps: 1) Cut the steel billet into multiple steel blocks, forge the steel blocks into rings, and perform rough machining, tempering heat treatment and fine machining on the upper and lower surfaces of the rings in sequence, so that the upper and lower surfaces of the rings are flat and the hardness of the rings is HRC28-32. 2) Prepare an induction coil (8) and use the induction coil (8) to perform induction hardening on the upper and lower surfaces of the ring so that the hardness of the upper and lower surfaces of the ring reaches HRC58-62. 3) A plurality of teeth (1) spaced apart are machined in the circumference of the ring to obtain a preform; 4) Prepare a contoured coil (9), cover the side surface of each tooth (1) with the contoured coil (9) in sequence and heat it with electricity so that the hardness of the side surface of each tooth (1) reaches HRC58-62; wherein, the shape of the contoured coil (9) matches the shape of the side surface of a single tooth (1) and covers the entire tooth (1); the teeth of the crusher blade are induction hardened multiple times using a contoured coil that matches the shape of a single tooth; 5) Grind the upper and lower surfaces of the preform and machine a spline hole or hexagonal hole (7) for mounting the drive shaft at the center of the preform to obtain a high wear-resistant and tough crusher blade. The ring consists of a first ring (2) and a second ring (3) from the inside out, wherein the width of the first ring (2) is 25 mm; in step 2), the range of the ring subjected to induction hardening is the second ring (3). The induction coil (8) is in the shape of a straight line, wherein the length of the induction coil (8) is the same as the radius of the ring; induction hardening includes heating the induction coil (8) by energizing it and placing it close to the upper and lower surfaces of the ring respectively, so that one end of the induction coil (8) contacts the outer surface of the ring and the induction coil (8) is parallel to one of the radii of the ring, rotating the ring around the center or rotating the induction coil (8) around the ring, so that the heating range of the induction coil (8) covers the upper and lower surfaces of the ring; in step 2), the depth of induction hardening of the ring is 3-5mm; in step 2), the induction hardening of the ring is medium frequency hardening, with a frequency of 1-10kHz.

2. The method for preparing high wear-resistant and tough crusher blades according to claim 1, characterized in that: The billet material is 40CrNiMoA or 42CrMo.

3. The method for preparing high wear-resistant and tough crusher blades according to claim 1, characterized in that: In step 5), the machining method is wire cutting or milling.

4. The method for preparing high wear-resistant and tough crusher blades according to claim 1, characterized in that: In step 2), after machining, ultrasonic testing is used to ensure that there are no defects inside the ring.

5. A high wear-resistant and high-toughness crusher blade obtained based on the high wear-resistant and high-toughness crusher blade preparation method according to any one of claims 1-4, characterized in that: It includes a ring-shaped body (4) with uniform thickness, and multiple teeth (1) of uniform shape are distributed circumferentially on the side surface of the body (4). Spline holes or hexagonal holes (7) penetrating the body (4) are provided at the center of the upper and lower surfaces of the body (4). The main body (4) includes a third ring (5) and a fourth ring (6) from the inside out. The width of the third ring (5) is 25 mm and the hardness of the third ring (5) is HRC28-32. The fourth ring (6) includes an upper surface layer, a central layer and a lower surface layer from top to bottom along the thickness direction. The thickness of the upper surface layer and the lower surface layer is 5 mm and the hardness of the upper surface layer and the lower surface layer is HRC28-62. The hardness of the central layer is HRC28-32. The hardness of each tooth (1) is HRC58-62.

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