Analysis of common problems with hammer heads of hammer crushers

Hammer crushers are widely used in the mining, construction, and aggregate industries for the crushing of various materials, such as limestone, coal, concrete, glass, and others. The hammer heads, which are the working components of the hammer crusher, are subject to significant wear and tear due to the impact and abrasion forces experienced during the crushing process. Here are some common problems with hammer heads and their analysis:

1. Abrasion and Wear:

- The most common issue with hammer heads is abrasion and wear caused by the continuous contact with the material being crushed. As the hammers rotate, they strike the materials, and the impact as well as the friction can gradually wear down the hammer heads. This wear not only reduces the efficiency of the crusher but can also lead to dimensional changes that affect the crusher's performance.

2. Erosion:

- Erosion can occur due to the presence of corrosive materials in the crusher feed. Materials such as acidic or basic substances can react with the hammer heads, causing chemical erosion. This erosion not only weakens the hammers but can also lead to surface corrosion, pitting, and reduced structural integrity.

3. Impact Fractures:

- Hammers are subjected to high-impact forces, and under certain conditions, such as operating with too much vibration or an imbalance in the crusher, the hammers can develop cracks or fractures. These fractures can compromise the structural integrity of the hammers and may lead to unexpected failures during operation.

4. Sieve Blockage:

- If the hammer heads are too large or the sieve opening is too small, fines can accumulate on the sieve, leading to blockages. This can cause the crusher to work harder, reduce throughput, and increase wear on the hammers as they attempt to crush material that is not properly sized for the crusher's capacity.

5. Inefficient Crushing:

- Over time, as hammer heads wear down, their shape and size can change, which may result in inefficient crushing. The hammers may no longer align properly with the sieve, leading to inconsistent particle size distribution and reduced overall efficiency of the crushing process.

6. Hammer Balance Issues:

- If the hammers are not balanced properly, they can cause additional vibrations in the crusher, which can lead to accelerated wear on the hammer heads and other components. Unbalanced hammers can also reduce the crusher's throughput and increase energy consumption.

7. Material Compatibility:

- The material from which the hammer heads are made must be compatible with the materials being crushed. If the hammers are not made from suitable materials, they may not withstand the forces and conditions encountered in the crusher, leading to premature failure.

To address these common problems, regular maintenance and inspection of the hammer heads are essential. This includes checking for wear, cracks, and balance issues, as well as ensuring that the hammers are the correct size and shape for the crusher's application. Replacing worn or damaged hammers in a timely manner can prevent further issues and maintain the crusher's performance. Additionally, selecting the right materials for the hammer heads and ensuring proper crusher operation can help extend the life of the hammers and improve the overall efficiency of the crushing process.