Impact Crusher Wear Liners: Everything You Need to Know
Know when to change parts and how to minimize your cost per ton.
Impact Crusher Wear Liners: Everything You Need to Know
Know when to change parts and how to minimize your cost per ton.
What are crusher wear liners?
Crusher wear liners are made from wear-resistant steel and protect the impact crusher housing from abrasion (wear). The impact-crushing process consumes your wear-liners and are a part of your operating costs.
Impact crushers typically have 2 types of wear liners:
Wear plates
typically armor the impact crusher housing's side, top, and back. They are smooth, easy to carry, and bolted on from the outside through wear bolts.
Impact plates
take the main brunt in the front with material impacting. Impact plates are mounted either on a single apron (RUBBLE MASTER style) or on two individual aprons. Impact plates can be either smooth or baffled.
If you neglect to change your crusher wear liners in time, you damage your impact crusher
Failing to change wear liners results in damaging your base frame and crusher housing, which are made from mild steel. This results in structural machine damage, lengthy downtime, and high repair costs. Additionally, you miss an opportunity to flip your consumables to extend the useable wear life.
Flipping and changing crusher wear liners in time makes you more money
Crusher wear liners should be checked daily to identify the wear rate and progress. Check out this blog article for the ideal daily routine for your impact crusher. Consult your crusher manufacturer for the ideal minimum tolerances.
What affects crusher wear?
The wear rate depends on the material, crusher settings, and the location within the impact crusher box. While some wear plates hold up a couple hundred operating hours, others last a couple thousand hours. Wear liners closer to the rotor wear faster due to a grinding effect than wear liners further away.
The following factors affect crusher wear negatively:
Feed Material
❌ The more fines
❌ The bigger the feed size
❌ The harder the material
❌ The more abrasive the material
❌ The higher the moisture content
Crusher Settings
❌ The higher the rotor speed
❌ The smaller the closed-side setting
❌ The closer the apron (or primary apron)
How long do crusher linings last?
Fines inside an impact crusher is like sand-blasting your consumables. A mobile scalping screen or a more efficient crusher pre-screen helps keep fines from entering the crushing chamber and improve your bottom line.
What is rock-on-rock crushing?
Rock-on-rock crushing can be achieved through a constant feed rate. Material entering the crusher box impacts with other materials rather than the crusher liners and thus keeps wear costs down. Rocks impact on rocks more than rocks impact on metal.
“Slow and Steady Wins the Race”
Material prep and sizing and choosing the proper shovel matter to achieve the lowest cost per ton.
Can you hard-face wear-liners?
It is possible to hard-face wear liners. Tests at the RUBBLE MASTER factory have shown that it doesn’t help with this type of wear. The hard facing gets off quickly, and the base material wears faster.
RUBBLE MASTER Impact Crushers come standard with Hardox 450 side liners
RUBBLE MASTER Mobile Impact Crushers feature 3/4” (20 mm) thick wear plates suitable for all recycling and rock-crushing applications. Optionally, the crushing chamber can be armored with extra thick 1¼” (30 mm) Hardox 600 side wear plates for highly abrasive applications.
In highly abrasive applications, you must frequently change wear plates without extra wear resistance. Choosing a thicker armor keeps you crushing longer and reduces your man-hour costs.
Side wear plates, wear bolts, and washers should be reordered once they are ¼” (5 mm) thin. Contact your authorized RUBBLE MASTER dealer for reordering wear parts.
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