https://cementl.com/ The TONGLI Cone Crusher Main Frame is made of low-alloy, high-strength cast steel, such as the universal ZG270-500 and the medium-load ZG310-570. Heavy-load hard rock models utilize alloy cast steels containing Cr and Ni, such as ZG40CrNiMo. These materials must meet yield strength ≥ 270MPa, elongation ≥ 18%, and pass a -20°C low-temperature impact test (impact energy ≥ 27J) to prevent cracking under low-temperature conditions.
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During the process design phase, a 3D model is first created using software like SolidWorks and UG. Focus is placed on optimizing stress concentration areas such as the feed flange and spindle hole step. Casting stress is reduced by increasing corner fillets (R ≥ 15mm) and adjusting rib thickness (80-150mm, in a randomized increment). Simultaneously, software like ProCAST is used to simulate the mold filling and solidification processes, predicting defects such as shrinkage and porosity. The size of the riser (height should be 1.2-1.5 times the thickness of the hot zone) and the pouring temperature are then adjusted, laying the foundation for subsequent casting.
Next comes the casting stage. Because the mainframes are mostly large, thick-walled castings weighing 5-50 tons (extremely large ones can reach over 100 tons), resin sand casting is the primary method used. When preparing the sand mold, use high-silica sand with a SiO₂ content ≥90% and a furan resin binder of 1.2-1.5%. Control the sand mold's air permeability to 80-120cm³/min and its green compressive strength to ≥0.25MPa. The sand mold is made by splitting the mold (usually into upper and lower boxes). Key areas such as the spindle hole and positioning stop are embedded with metal core bones or cast iron chillers (20-50mm thick) to accelerate local cooling and reduce shrinkage cavities. Metal smelting is performed in a 5-10 ton electric arc furnace or medium-frequency induction furnace, using a mix of "60-70% scrap steel, 20-30% pig iron, and alloying additives." Carbon content is strictly controlled at 0.25-0.45%, and S/P ratios are both ≤0.04%.
Once the molten steel reaches a temperature of 1560-1620°C and its composition meets acceptable standards, it is poured using a bottom-fill method with a stepped gate at a controlled rate of 5-10 kg/s to prevent the molten steel from directly impacting the sand mold. After pouring, the mold is naturally cooled for 24-72 hours (increasing with unit weight). Once the temperature drops below 200°C, the mold is desanded using a vibrating shakeout machine.
Shot blasting (1.5-3mm diameter, 0.5-0.8MPa pressure) and manual polishing are then performed to remove scale, adhering sand, and risers (leaving a 10-20mm machining allowance), ensuring a surface roughness of ≤Ra25μm.
After casting, the casting enters the heat treatment strengthening phase. A three-stage process, annealing, normalizing, and tempering, is used to eliminate internal stresses and improve mechanical properties. First, stress relief annealing involves heating the casting to 550-650°C at a rate of ≤80°C/hour. The holding time is calculated based on the wall thickness (2-3 hours/100mm, typically 8-12 hours). The casting is then slowly cooled in the furnace (≤50°C/hour) to below 200°C.
After heat treatment, precision machining begins, ensuring precise assembly of the mainframe, adjustment ring, spindle, and other components. First, the bottom and top flanges are milled to ensure parallelism ≤0.1mm/m and flatness ≤0.05mm/m, respectively. This serves as a positioning reference for subsequent machining. During the machining of key bore systems, the spindle holes are machined using a three-step process: rough boring, semi-finishing, and finishing. The hole diameter tolerance is controlled to H7 (e.g., a φ500mm spindle hole tolerance of +0.039 to 0mm), with cylindricity ≤0.015mm, surface roughness ≤Ra1.6μm, and verticality of the step surface within the hole ≤0.01mm/m.
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