Five signs of hammer wear in a crusher: Replace them promptly to avoid decreased efficiency!
Crusher hammer wear can impact equipment efficiency and finished product quality. Promptly identifying signs of wear can prevent further losses. Here are five key wear signs and recommended solutions
Signal 1: Abnormal material particle size
Symptoms: 10-15% of the finished product contains oversized particles or the particle size distribution fluctuates by more than ±3%.
Cause: Increased clearance between the hammer working surfaces due to wear (a gap greater than 8mm seriously impacts screening).
Signal 2: Rising bearing temperature
Symptoms: Bearing temperature rise exceeds +45°C above ambient temperature (normally less than +35°C).
Association: Hammer wear increases load torque, which is transmitted to the bearings.
Signal 3: Increased noise and vibration
Symptoms: Frame vibration exceeds factory standards by 30%, accompanied by a regular knocking sound.
Cause: Uneven hammer wear disrupts rotor dynamic balance.
Signal 4: Continuous Decline in Output
Symptoms: Output decreases by more than 20% at the same power, or the crushing time for the same material is significantly prolonged.
Cause: Blunting of the hammer blades, resulting in reduced impact force.
Signal 5: Increased Metal Impurities
Symptoms: Magnetic metal impurities in the material >100ppm (normal <50ppm).
Root Cause: The hardened surface layer of the hammers wears away, causing the base material to begin flaking.
Golden Rules for Replacement Operations
Use a symmetrical replacement method (replace at least four hammers in symmetrical positions each time).
We recommend using D507 tungsten carbide overlay welding, which can extend the lifespan by 2-3 times.
Replace the screen (maintain a 3-5mm gap between the hammers and the screen).