Composite Milling Cone With Titanium Carbide Reinforcement
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Solution Overview
Problem
Current methods for modifying the hardness and compression resistance of milling cones in compression crushers are limited, primarily focusing on surface modifications that do not effectively address simultaneous mechanical stresses, wear, and impact resistance, leading to high wear and consumption of the parts.
Innovation Solution
A composite milling cone with a reinforcement structure featuring alternating macro-microstructures of titanium carbide particles within a ferrous alloy matrix, achieved through self-propagating high temperature synthesis (SHS) of titanium carbide granules, providing enhanced resistance to wear and impact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If surface modification techniques are used to improve hardness and wear resistance, then surface hardness is improved, but the reinforcement depth is limited to a few millimeters and cannot withstand significant localized stresses
Solution Approach 1:
The patent applies preliminary action by incorporating reinforcement granules (titanium carbide, tungsten carbide, or hardox) into the mold cavity before casting the ferrous alloy. This allows the reinforcement elements to be positioned in advance at specific locations where high wear and stress resistance are needed, ensuring deep and targeted reinforcement throughout the milling cone structure rather than just surface-level modification.
Solution Approach 2:
The patent implements local quality by using granules with reinforcement properties distributed at specific locations within the milling cone structure. The granules can be concentrated in areas subject to highest wear and stress (such as the working surface and impact zones), creating non-uniform local reinforcement that matches the actual stress distribution patterns in the crusher application.
2Strength
If tungsten carbide inserts are mechanically set in housings to reinforce surfaces, then surface reinforcement is achieved, but the reinforcement is discontinuous and requires pre-provided housings
Solution Approach 1:
The patent merges the reinforcement elements directly into the milling cone body through the casting process, eliminating the need for separate housings or mechanical insertion structures. The granules are embedded within the ferrous alloy matrix during a single casting operation, creating an integrated structure where the reinforcement and base material form a unified component without additional structural elements.
Solution Approach 2:
The patent replaces the mechanical insertion system (housings, press-fits, or threaded connections) with a metallurgical bonding approach. The ferrous alloy matrix naturally bonds to the reinforcement granules during casting and solidification, substituting complex mechanical assembly structures with a simpler metallurgical joining process that occurs automatically during manufacturing.
3Duration of action of stationary object
If alternating areas of high and low wear resistance are created on the cone surface, then lifetime is extended through stress distribution, but the structure does not provide sufficient resistance to simultaneous localized stresses
Solution Approach 1:
The patent creates a composite material structure by combining ferrous alloy matrix with dispersed reinforcement granules (titanium carbide, tungsten carbide, or hardox). This composite provides both the toughness of the ferrous alloy and the extreme hardness and wear resistance of the carbide granules, enabling the material to simultaneously resist both wear and high localized compressive stresses that alternative approaches cannot handle.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The composite structure significantly increases the lifetime of milling cones by distributing titanium carbide particles throughout the material, reducing crack formation and propagation, and maintaining flexibility in application parameters, resulting in improved resistance to wear and impact.
Implementation Method 1
infiltration of the millimetric and micrometric interstices by said high temperature cast ferrous alloy
Implementation Method 2
the heat of said casting triggering an exothermic self-propagating high temperature synthesis (SHS) of titanium carbide within said precursor granules
Data Source
AI summary
The present invention discloses a composite milling cone for compression crushers, said milling cone comprising a ferrous alloy at least partially reinforced with titanium carbide according to a defined geometry, in which said reinforced portion comprises an alternating macro-microstructure of millimetric areas concentrated with micrometric globular particles of titanium carbide separated by millimetric areas (2) essentially free of micrometric globular particles of titanium carbide, said areas concentrated with micrometric globular particles of titanium carbide forming a microstructure in which the micrometric interstices between said globular particles are also filled by said ferrous alloy.