spare parts of spring cone crusher

Spare Parts of Spring Cone Crusher: An Overview

The reliable operation and longevity of a spring cone crusher are fundamentally dependent on the quality, proper selection, and timely replacement of its critical spare parts. This article provides a detailed overview of the essential wear parts within a spring cone crusher, including the mantle and concave, main shaft and bushings, springs, and drive components. Understanding their function, wear characteristics, and maintenance intervals is crucial for minimizing downtime and optimizing crushing performance. We will examine the factors influencing part life, compare material options, and present practical guidance for inventory management and replacement strategies.

1. Critical Wear Parts and Their Functions

The crushing action in a spring cone crusher occurs between two manganese steel surfaces: the mantle (attached to the moving head) and the concave (or bowl liner, fixed inside the adjusting ring). These are the primary wear parts and directly determine product size and output. The main shaft transmits the crushing force, supported by eccentric bushings which create the gyrating motion. Frame bushings provide additional support. The spring assembly is a safety feature that allows the crusher to discharge uncrushable material (tramp iron) by expanding the crushing cavity, protecting the machine from catastrophic damage.

2. Material Selection and Part Life Comparison

The choice of material for wear parts significantly impacts service life and cost-per-ton crushed. The most common material is manganese steel (typically 14% or 18% Mn), known for its work-hardening property—it becomes harder under impact. Alternatives include composite materials or martensitic steels for specific abrasive applications.

Part	Primary Material Options	Key Wear Mechanism	Factors Influencing Life
Mantle & Concave	Austenitic Manganese Steel (Mn14%, Mn18%), Martensitic Steel	Abrasion, Impact Fatigue	Feed material abrasiveness (SiO2 content), feed size distribution, crusher setting (closed side setting), throughput.
Eccentric Bushing	Bronze (e.g., SAE 67), High-Lead Bronze	Adhesive Wear, Fatigue	Lubrication quality & cleanliness, alignment, load conditions.
Main Shaft	Forged Alloy Steel	Bending Fatigue, Minor Surface Wear	Shock loads from uncrushables, proper fit with bushings.
Springs	High-Carbon Steel / Alloy Spring Steel	Fatigue, Relaxation	Number of overload events, exposure to corrosive conditions.

Abrasive feed material like granite or gravel with high quartz content will wear liners faster than softer limestone. Operating with a consistently small closed-side setting increases wear rates compared to a coarser setting.

3. Maintenance & Replacement Strategy

A proactive maintenance strategy is based on regular inspection and monitoring.

• Wear Measurement: Regularly measure mantle and concave wear using profile gauges or cavity measurement tools. Mantles can often be rotated 180 degrees to utilize unused sections.
• Lubrication: Oil analysis is critical for monitoring bushing health. Contamination or metal particles in the oil indicate advanced wear.
• Spring Inspection: Check spring length periodically against original specifications; a set of springs should be replaced together if any show significant permanent set or cracks.

Replacing liners in matched pairs (mantle and corresponding concave) ensures optimal geometry for crushing efficiency and product gradation.

4. Real-World Case Study: Limestone Quarry Operation

A quarry in Texas processing abrasive limestone was experiencing premature concave failure every 120,000 tons. The crusher was operating at a tight 19mm CSS to produce chip stone for asphalt.

• Analysis: An audit revealed inconsistent feed sizing with occasional oversized slabs causing high momentary pressure on one side of the concave.
• Solution: The operation implemented two changes:
  1. They switched from a standard Mn18% concave to a modified-design concave with a thicker initial profile in the high-wear zone.
  2. They installed a pre-screening grizzly to remove +10" oversize before the crusher.
• Result: Concave life increased by approximately 40%, reaching 170,000 tons before replacement was needed. The more consistent feed also improved overall throughput and product shape.

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FAQ

Q1: How do I know when to replace the mantle and concave?
Replace them when worn profiles lead to unacceptable product size enlargement (loss of CSS control), a significant drop in throughput capacity, or when metal-to-metal contact risks damage to underlying structures. Most manufacturers provide minimum thickness guidelines.

Q2: Can I mix mantle and concave brands from different manufacturers?
It is strongly discouraged. Mantles and concaves are engineered as a system; mismatched profiles can lead to poor crushing geometry, reduced efficiency, accelerated wear on both parts, potential packing issues, and increased power draw.

Q3: Why is lubrication so critical for the eccentric bushing?
The bronze eccentric bushing operates under high pressure with sliding motion against the steel shaft. Clean oil provides a hydrodynamic film preventing metal-to-metal contact. Contaminated or degraded oil leads to adhesive wear (scoring), increased friction heat generation which can cause bearing seizure ("burned" bushing), resulting in costly downtime.

Q4: What are common signs of failing springs?
Visible cracks or permanent shortening ("taking a set") are clear indicators. Uneven discharge settings across different sides of the crusher can also point to uneven spring compression/pressure due to failure.

Q5: Should I always keep a full set of spare parts in stock?
A cost-effective inventory strategy balances part lead time against storage costs.For most operations,critical spares include: at least one full set of mantle/concave liners,a main shaft assembly,eccentric bushing sets,and springs.High-wear items like liners should be stocked based on your predicted consumption rate.For less critical items with shorter lead times,a monitored minimum stock level may suffice.Consult your OEM's recommended spare parts list as baseline guidance