Crusher Wear Element Metal Matrix Composite
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Crushers, particularly those using hard steel, face issues with rapid wear and deformation due to unbreakable objects during the crushing process, leading to reduced elongation at break and frequent maintenance needs, especially when processing fine materials like oil sand.
Innovation Solution
A crusher design featuring a stationary crushing element with wear protection elements made from a metal matrix composite material, incorporating a hard metal or ceramic insert with a porous structure, where the metal matrix material is infiltrated into the insert, providing high wear resistance and elongation at break, and strategically attaching these elements to carriers for easy replacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If high-hardening steel is used for crushing elements, then wear resistance is improved, but elongation at break is reduced
Solution Approach 1:
The invention uses a composite material consisting of a metal matrix (providing ductility and elongation at break) combined with hard metal or ceramic particles (providing wear resistance). This composite structure allows the crushing element to simultaneously achieve high wear resistance and high elongation at break, resolving the contradiction between these two properties.
2Duration of action of stationary object
If harder material is used to improve wear resistance, then maintenance frequency is reduced, but susceptibility to failure under high load increases
Solution Approach 1:
The composite material combines hard metal or ceramic particles embedded in a metal matrix, creating a structure that is both wear-resistant and ductile. The metal matrix absorbs impact loads and prevents catastrophic failure, while the hard particles provide wear resistance, thereby extending service life without compromising reliability under high loads.
3Duration of action of stationary object
If wear-resistant steel is used, then crushing element durability is improved, but rapid wear occurs when processing fine materials
Solution Approach 1:
The composite material with hard metal or ceramic particles in a metal matrix provides superior wear resistance specifically for fine materials processing. The hard particles resist abrasion from fine particles, while the metal matrix maintains structural integrity, thereby reducing wear rate and extending durability simultaneously.
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 solution enhances wear resistance and elongation at break, preventing failure under high loads and allowing for efficient maintenance by using a combination of high-temperature-resistant steel and hard metal or ceramic particles, effectively extending the lifespan of crushing elements.
Implementation Method 1
The wear-resistant insert has a porous structure and is at least partially cast into the wear-resistant element, such that the metal matrix material is at least partially infiltrated into the wear-resistant insert
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
The invention relates to a breaker (10 for comminuting material, comprising a breaking chamber (20) having a loading area (16), into which material to be comminuted is loaded, and a breaking gap (22) for breaking the material, wherein the breaking chamber (20) tapers from the loading area (16) to the breaking gap (22), wherein the breaker (10) has a stationary breaking element (14) and a movable breaking element (12), which delimit the breaking chamber (20), and wherein the stationary breaking element (14) has a wear-protection element (24), which is formed from a metal matrix composite material having a wear-protection inlay (30) made of a hard metal and/or of ceramic. The invention further relates to a method for producing a wear-protection element (24) of a stationary breaking element (14) of a breaker (10), comprising the steps: positioning a wear-protection inlay (30) made of a hard metal or ceramic in a casting mould for casting the wear-protection element (24), and casting the wear-protection element (24), such that the wear-protection inlay (30) is at least partly enclosed by the cast material of the wear-protection element (24).