Cone Crusher Shell

Cone‍‌‍‍‌ crusher frames under continuous crushing loads must deliver structural stability, accurate fitting, and have high impact resistance and low fatigue failure characteristics, which are equally important.

Structural deformation of component mis alignment as well as local stress concentration and premature wear are all potential issues that could result from frame deficiency in rigidity, inadequate distribution of stresses, or dimensional deviations at critical locations after repetitive crushing.

These sorts of problems usually lead to multiple fitting operations, unexpected replacement of components, elongated maintenance periods, and ultimately rising operating costs for purchasing and maintenance departments.

This implies that purchasing department’s main requirement is not simply the use of high-strength steel of the frame but whether the crusher structural design, the material processing techniques employed, machining precision and inspection results actually suit the requirements in practical application of the crusher.

Our Solution

We fabricate frame of ZHUOYUE cone crusher through structural optimization, alloy steel casting, heat treatment, and CNC machining, depending on the actual crusher model, OEM part number, drawing, or technical specification.

How we react to major risk of failure:

• Structural deformation: To check where the structural design would distribute the forces, we rely on static and dynamic finite element stress analysis, which is a part of a design optimization. On top of that, we locate areas of stress concentrations and, thus, structural failures more likely to happen. Before the mass production these areas should be addressed.

• Material and fatigue properties: Frame fabrication consists of high-strength alloy structural steel and secondary quench and tempering treatments. The specified material strength gives the material tensile strength as ≥980 MPa with compressive strength of ≥1.150 MPa after verification based upon the relevant material test report.

• Assembly discrepancy: Dimensional critical features are machined by using CNC machines according to both the final drawings and specifications. Presently, the product specification allows a maximal dimensional deviation of ±0.02 mm and mating gap of ≤0.01 mm during assembly. However, prior to the use of these figures as binding provisions in a contract, they must be checked against the latest approved drawing.

Environmental effects in the long term: The surface of a product and its protection against corrosive media can be ensured by multi-stage cleaning procedures together with an anti-corrosion coating. In this way, the surface is safeguarded against moisture, dust, and ore-related working conditions. On customer request, the specific coating system and the testing standard can be provided.

Quality Verification: At the time of shipment, all final checks shall be done of the materials concerning their composition, sizes, hardness and the components’ finish that meet technical specifications approved by the client.Non-destructive tests, if deemed necessary, can also be carried out visually.

Advantages for the buyer:

• Possible prevention of deformation and dimensional mismatch under heavy-load operation

• Less assembly gaps of crusher parts according to the standard

• Procurement documentation material and dimension inspection records are traceable

The risk of requiring major modifications is reduced and replacement of the old frame can be done much more smoothly

Instead of a frame that conforms to a general frame type specification, a process has been tailored to a validated crusher model and the technical requirements.

Kindly give us the name of your crusher manufacturer, the model or OEM part number if it is available. Alternatively you can also send us the original drawing, CAD file or measurements if you possess those. Our team of engineers will carry out a final review of your design requirements after which the fabrication shall ‍‌‍‍‌commence.

Product Advantages:

ABOUT US

As a mining equipment parts supplier specializing in crusher spare/ wear parts and custom-machined parts with technical support, ZHUOYUE has a core team that combines more than 10 years’ experience with in-depth knowledge of the production processes of these parts.

First of all, for cone crusher structural components we identify the proper part in terms of specifications by comparing with the crusher model, OEM part number, drawing on file, or customer sample before starting the production of the part.

Facuity

• Approximately 4000 m² production base in Shenyang, Liaoning, China24 R&D and technical staff

• 14 production lines: 10 machining, 2 welding, 2 assembly lines

• Manufacturing capacity ~ 2,000 tons per year

• Maximum single-part processing capability up to 150 tons depending on equipment and production requirements

• Manufacturing capabilities also include casting/forging if possible, heat treatment, precision machining, surfacing, finishing, and quality inspections

Quality‍‌‍‍‌ System

The ZHUOYUE quality management system includes a series of documented procedures for inspecting quality at the receipt of materials stage, during manufacturing, and also prior to shipment.

In addition, ZHUOYUE has applied for ISO 9001 (quality management system) certification. The methods of inspection and standards applicable to materials, product specifications, and customer requirements are accordingly verified.

Customers and Export Markets

ZHOUYUE serves customers in mining, sand and gravel, and construction-related applications across East South, the Middle Eastern, African, and South American regions.

We can only disclose our customer names and project information if an authorized request has been made and appropriate clearance given.

Quality Control and Inspection

At various stages of the manufacturing cycle, quality inspection is carried out in line with the drawings, materials specification, and technical requirements which have been agreed upon.

• Checking whether material grade matches the approved quality specification

• Conducting chemical composition testing whenever it is necessary

• Verifying the material certificate and heat-number when necessary

• Looking at the materials visually to spot any potential errors

Quality inspection of parts and components in the manufacturing phase

• Evaluation of casting's look and surface

• Dimensional verification through approved CAD drawing

The features stated are to be looked at and the following aspects checked: mounting surfaces; bores; holes; threads; and other interfaces.

Check for presence of cracks and defects from casting (which are visible), machining damage.

Heat treatment records and hardness testing must be carried along with the requirement of the ‍‌‍‍‌standard.

Non-Destructive Testing

In the absence of NDT specification in components and areas, inspection may involve the use of the following methods:

• UT - ASTM A388 / GB/T 6402

• MT - ASTM E709 / GB/T 15822

• PT - ASTM E165

Based on the type of material, the component design, and the buyer's needs, the suitable NDT technique and criteria of acceptance are set.

Inspection Before Shipment

• Comparing dimensions of work to that of approved drawing

• Checking the look and surface treatment of material

• Confirming presence of necessary test reports

• Checking of packaging prior to dispatch

As per order requirement we are able to deliver inspection reports.

Order Information

Warranty

ZHUOYUE provides warranty coverage for agreed manufacturing defects and non-conformance to the approved technical specification, subject to the terms stated in the sales contract.

Customization and Replacement Support

At ZHUOYUE, we support customers with replacement cones crusher frames and are also able to offer customization, as long as the equipment information is available.

We have an open-door policy, and we allow different types of customization based on:

Crusher model, OEM part number

Customer drawings

Existing component samples

Material specification required

Critical dimensions and mounting interfaces

Machining requirements

Surface treatment requirements

Inspection and documentation requirements

In the absence of original drawings, we can also consider available sample measurements and technical details to decide whether a replacement drawing is feasible that the buyer can approve.

FAQ

Q1:‍‌‍‍‌ How do you verify if the cone crusher frame is suitable for your equipment?

A: Fitment is checked by verifying the brand and model of the crusher, OEM part number, original drawing, or through a customer-provided sample. Critical dimensions and interfaces for mounting are analyzed before the actual production.

Q2: Is it possible to produce a cone crusher frame using your reference by OEM part number?

A: Definitely yes. OEM part numbers may also be employed as references for a technical review. Nevertheless, we advise you to share the crusher model as well as the original drawing or sample, if available, so that the necessary requirements can be verified and the production started only after that.

Q3: What data have to be specified in case of custom fabrication of a cone crusher frame?

A: Kindly share crusher brand and model, OEM part number, original drawing, photos, main dimensions or a sample of an already existing component. If specified, materials, machining, surface-treatment and visual inspection requirements may also be shared.

Q4: Can you produce a new frame based on a heavily used/damaged/old component of the cone crusher?

A: In cases where the original drawing is lost or cannot be obtained, sample-making or sample-based manufacturing methods may be utilized to judge the part's dimensions and characteristics. After assessing the available sample and dimensional specifications, it is still possible to have a technical drawing prepared which may first be confirmed by production where necessary.

Q5: Which materials do you use for cone crusher bodies?

A: Materials used are selected based on the equipment and technical requirements that have been agreed upon or are clear. If necessary, high-strength alloy structural steels will be used and the material grade is finally agreed upon before commencing with the production stage.

Q6: What inspection documents are available from you?

A: Inspection reports will be supplied as part of the production documents. Based on order terms, we may prepare documentation such as material certificates, dimensional inspection records, hardness or heat treatment records, and NDT reports in case that UT, MT or PT has been carried out.

Q7: What is the minimum order quantity (MOQ) of a cone crusher frame?

A: As with stock availability, product category, and whether the product is a standard replacement or custom-made component, MOQ changes with frame models. After confirmation and negotiation, quantity requirement has been fixed in quotation.

Q8: What is the lead time?

A: Lead time is a combination of frame model, material needs, drawing approval, machine workload and production schedule. We will provide you with the lead time after we have given you quotation.

Q9: How are large cone crusher frames packaged for export?

A: For overseas shipments, large structural parts should be carefully packed in a sturdy export container such as a steel cage or a wooden case, taking into account the characteristics of the component like size, weight and transport conditions.

Q10: Which delivery terms do you support?

A: We have both EXW and FOB terms. As to other delivery solutions, they will be figured out after the order.

Q11: Can you provide inspection reports before shipment?

A: We can send you a copy of the inspection records agreed up on with your order. As to the records to be provided, they will be depending on what inspection items have been specified and the production process steps.

Q12: Can you support OEM or customized cone crusher frame requirements?

Custom manufacturing can be assessed as per the crusher model, OEM part number, drawing, sample, material specification, machining requirements, and inspection ‍‌‍‍‌standards