The sand maker cutter head, a pivotal wear-resistant component also known as the sand maker hammer head, plays a vital role in the operational efficiency of impact sand makers, crushers, and other mining machinery. Its superior performance is crucial in enhancing crushing efficiency, minimizing energy consumption, and extending the service life of your equipment.
I. Core Performance
1. High Wear Resistance
- Material Advantages : Crafted from high-chromium alloy, high-manganese steel, tungsten carbide alloy, and composite wear-resistant materials, this cutter head boasts a surface hardness of HRC55-65 (Rockwell hardness), setting a new benchmark in wear resistance compared to standard steel.
- Application Scenarios : Ideal for tackling high-hardness ores such as granite, basalt, and cobblestone, this cutter head minimizes wear frequency, significantly reducing replacement costs and boosting productivity.
2. Impact Resistance
- Structural Design : Featuring a composite structure of "strong and tough core + wear-resistant surface," employing bimetallic liquid-liquid composite casting technology, it masterfully balances hardness with toughness, enduring high-speed impacts from ores without fracturing.
- Dynamic Adaptability : During high-speed rotations, reaching linear velocities of up to 60-100m/s, this cutter head reliably crushes large material chunks, effectively preventing cracking or deformation due to impacts.
3. High Temperature Resistance
- Thermal Stability : Utilizing high-temperature-resistant alloy materials, including nickel and molybdenum, it maintains exceptional performance even in high-temperature environments (300-500ºC) caused by friction during crushing, thereby averting material softening and failure.
4. Precise Adaptability
- Model Customization : Tailor the size, weight, and installation method of the cutter head to match specific sand maker models (such as 1140, 1360) and rotor structures, ensuring seamless integration with components like the main shaft and hammer shaft, while minimizing vibration and noise during operation.
II. Key Features
1. Process Optimization
- Precision Casting : Employ advanced processes like investment casting and lost foam casting to achieve impeccable dimensional accuracy (tolerance ±0.5mm) and surface finish, thereby reducing both installation and debugging time.
- Heat Treatment Strengthening : Through quenching and tempering processes, the material's comprehensive performance is significantly enhanced. Notably, the hardness of the wear-resistant layer of high-chromium alloy cutter heads increases by 20%-30%, while core toughness retains over 40%.
2. Long-Life Design
- Life Comparison : Under identical working conditions, high-quality alloy cutter heads offer a service life 2-3 times greater than ordinary manganese steel cutter heads. For example, in granite crushing, while ordinary cutter heads last approximately 500-800 hours, high-chromium alloy cutter heads can reach 1500-2000 hours.
- Wear Repairability : Designed for longevity, some cutter heads support surfacing repair, using wear-resistant electrodes or flux-cored wires, thereby extending the operational cycle and significantly reducing costs.
3. Convenient Installation and Maintenance
- Quick-Release Structure : Featuring bolt fixation and wedge locking designs, allowing for single-person quick replacements, effectively cutting downtime (ensuring single replacement times within 1-2 hours).
- Balance Optimization : Undergoes rigorous dynamic balance testing (accuracy grade G6.3) before dispatch, ensuring stable rotor operation and reducing equipment wear over time.
4. Environmental Protection and Energy Saving
- Efficient Crushing : Our cutter head is engineered with a sharp cutting edge and an expertly crafted angle design, ranging from a precise 30° to 45°, ensuring a higher one-time crushing success rate. This innovative approach significantly reduces over-crushing and notably cuts energy consumption by 10% to 15%, offering remarkable efficiency for sand applications.
- Low Dust Emission : The cutting-edge design optimizes the crushing trajectory, effectively minimizing material splashing. When paired with the state-of-the-art dust removal system incorporated into the equipment, it significantly lowers dust concentration at the worksite, fully aligning with stringent environmental protection standards.
III. Selection Suggestions
- According to Material Hardness : Tailor your choice based on rock type-opt for high-manganese steel cutter heads for soft rocks such as limestone. For more demanding, hard rocks like quartzite, our high-chromium alloy or tungsten carbide cutter heads stand out as the perfect choice, ensuring enhanced performance and durability.
- According to Equipment Power : Large-scale sand makers with power exceeding 300kW should be equipped with robust, thickened cutter heads to withstand high-impact operations. Conversely, smaller equipment can benefit from lightweight yet durable alloy cutter heads, optimizing performance without compromising on efficiency.
- Pay Attention to Supplier Processes : It is crucial to select manufacturers who excel in testing capabilities, offering services such as spectral analysis and rigorous wear testing, including wet sand wear tests. This ensures the material uniformity and performance stability of the cutter heads, guaranteeing long-lasting reliability and superior quality.
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