Test information of BV210825 Jawmaster 1206 HD Cone crusher CH440

Test information of BV210825 Jawmaster 1206 HD Cone crusher CH440

 

The feedback from our European customers just now, everything makes the facts speak!

 

Hello Fernando,

I have gathered some information and pics. from our previous order regarding the:

A.Jawmaster 1206 HD

400.0484-002 Jaw Plate 2 pcs. Mn22%Cr2%Mo0.5%Tic Insert

 

B.Cone crusher CH440

442.9073-03 Mantle 1 pc. Alloy Steel With Tic Insert

442.8419-03 Concave 1 pc. Alloy Steel With Tic Insert

 

Briefly, this test was quite successful. The jaw plates performed well and the operation time was twice as good as their normal ones: 29 000 t and 53 000 t. The wear was even and the jaw plates could run to the end of the wear limits. From the material technology point of view I think this is a good set up for these circumstances. What do you think is it worth to test any other options? Here are some pictures:

 

 

BOGVIK customized Mn22%Cr2% with Tic Insert
The service life is expected to be 100%-150% higher than that of OEM parts！
We can also provide similar solutions for C110, C120, C125, C140, C145, C150, C160

 

BV Titanium Carbide Insert

At the forefront of engineering innovation for two decades, BOGVIK was the first Succeeded company to offer titanium carbide (TIC) wear parts in China and has recently added ceramic reinforced alloy (CRA) and tungsten carbide (WC) options for a number of parts. BOGVIK is also well-known for their revolutionary diverter valves allowing rapid in-line maintenance of slurry and cement transportation.

Our commitment to quality and dedication to our customers has resulted in long-lasting relationships with distributors, mines and processing plants worldwide. BOGVIK with Titanium Carbide (TIC) inserts deliver outstanding durability. Impactors/Blow Bars, Jaw Crusher Plates, Hammers, and Breaker Blocks are offered in TIC versions. We chose the rhino to symbolize the toughness of the titanium carbide rods that give our wear parts such power.

 

Titanium Carbide Rods Technical Parameters:

· Hardness (ISO 3878): 82.5±0.5 HRA

· Density : 6.2 ±0.2 g/cm3

· TRS (ISO 3327): 1800-2000 N/mm2

· Average Grain Size: 2.0 ±0.5 μm

· Porosities: A02B00C00

· CHEMICAL: TIC (47%)-Fe(37%)-Ni (2.0%)- MN (10.0%) Other(4.0%)

Titanium Carbide Rods Types:

Diameter range(mm): (D)8-45mm
Length range(mm): (L)30-100mm
Hot sale sizes(mm): D12x50 D14x60
D12x40 D14X40 D12X60 D12*80
D16X90 D20X40/50/60

 

Features

BOGVIK titanium carbide (TIC) jaw crusher wear parts are designed to increase the wear life of wear parts in abrasive environments. Titanium carbide columns are cast within proprietary alloys for added strength and durability.

BOGVIK proprietary alloys and innovative designs result in long wear life compared to other OEM replacements. Titanium Carbide (TIC) options are available for even longer wear life. Custom designed to suit your needs, BOGVIK Jaw Plates and Cheek Plates are engineered to suit the specific needs of your application.

 

Benefits

· Increased Wear Life – BOGVIK’ s unique TIC insert jaw plates design features a strengthened high-wear zone for maximum usable wear life        and reduced breakage.

· Strengthens as It Works – Jaw plates body is cast in durable manganese steel (Mn18Cr2) that gets harder the longer you work it.

· Consistent Wear – More consistent wear profile for uniform product output and increased efficiency.

· Titanium Carbides –TIC inserts currently available are 20mm, 40mm, 60mm, and 80mm depths.

· Fewer Change-Outs – Greater durability and longer wear life means fewer change outs, more up-time, and lower maintenance costs

 

 

Jaw Plate Wear Life Increase from 3.5 to 30 Days

BOGVIK supplies mine with Titanium Carbide jaw crusher wear parts to combat extremely hard and abrasive material.

BACKGROUND

Our Finland customer, who has a C160 jaw crusher. Its jaw crusher parts from the local agency, its fixed jaw plate have 7 days working life and movable jaw plate have 14 days working life.

CHALLENGES

When the application changed to underground only, the increased hardness and abrasiveness of the material found underground reduced the wear life of the original parts. Our customer wants to increase the output, so need the jaw crusher wear parts to have a longer time.

SOLUTION

BOGVIK custom-designed a set of TIC insert jaw plates which featured titanium carbide (TIC)inserts in the high wear areas of the manganese alloy jaws. This design improvement increased the wear life, the tic inserts fixed jaw plate span life increase to 15 days and the tic insert movable jaw plate span life increase to 90 days.

PERFORMANCE & RESULTS

This dramatic improvement of over 8.57 times the wear life of the original manganese jaws was met with extreme satisfaction. The engineers at our customer expressed confidence in the movable jaw and do not feel the need to test its wear life as they “expect exceptional functioning knowing the performance of the fixed jaw”.

ADVANTAGES OF TITANIUM CARBIDE

· Increased Wear Life - BOGVIK’ s unique TIC hammer and blow bar design features a strengthened high-wear zone for maximum usable wear      life and reduced breakage.

· Strengthens as It Works - Hammer body is cast in durable manganese steel (M19) that gets harder the longer you work it.

· Consistent Wear - More consistent wear profile for uniform product output and increased efficiency.

· Titanium Carbides - TIC inserts currently available are 20mm, 40mm, 60mm, and 80mm depths.

· Fewer Change-Outs - Greater durability and longer wear life means fewer change outs, more up-time, and lower maintenance costs.

 

BOGVIK TITANIUM CARBIDE WEAR PARTS IN THE FIELD

Case Study 1: Recycling Plant, 1213 Impact Crusher (85% concrete, 15% asphalt)

Before: Competitor’s ceramic-embedded blow bars shattered after crushing 11000 Tons.

After Switching to BOGVIK TIC: BOGVIK M19 TIC Blow Bars crushed 38000 Tons: 3.45 X wear life!

 

Case Study 2: Cement Plant, 341lb Universal/ ThyssenKrupp Hammers (limestone)

Before: Competitor’s M8 hammers delivered a wear life of 450-600 hours before replacement.

After Switching to BOGVIK TIC: BOGVIK TIC hammers with 40mm pins averaging 1000-1300 hours: up to 2.22 X wear life! TIC hammers with 60mm pins projected wear life 1500 hours: up to 2.5 X wear life!

 

Case Study 3: Cement Plant, 1550 Pennsylvania Hammer Mill (limestone)

Before: Competitor’s high chrome hammer lasted for 2 weeks before breaking.

After Switching to BOGVIK TIC: BOGVIK TIC M2 Hammers and suspension pins lasted 8 weeks: up to 4 X wear life!

 

 

TIC Insert Cone Liner & Bowl Liner

Features

When it comes to Replacement tic insert cone liner and bowl liner, BOGVIK has been crushing the market for decades. If you demand the peace of mind that comes with ISO 9001-certified, fully-guaranteed and warranted replacement parts for your cone crusher. BOGVIK can supply tic insert cone crusher wear parts.

BOGVIK titanium carbide (TIC) cone crusher wear parts are designed to increase the wear life of wear parts in abrasive environments. Titanium carbide columns are cast within proprietary alloys for added strength and durability.

Benefits

· Increased Wear Life – BOGVIK’ s unique TIC insert cone liners and bowl liners design features a strengthened high-wear zone for maximum        usable wear life and reduced breakage.

· Strengthens as It Works – Concaves and mantles body are cast in durable manganese steel (Mn18Cr2) that gets harder the longer you work it.

· Consistent Wear – More consistent wear profile for uniform product output and increased efficiency.

· Titanium Carbides –TIC inserts currently available are 20mm, 40mm, 60mm, and 80mm depths.

· Fewer Change-Outs – Greater durability and longer wear life means fewer change outs, more up-time, and lower maintenance costs

Study Case

40 mm TIC Cone liners Last 3-times Longer Than normal manganese cones

BOGVIK’ s innovative titanium carbide Cone liners inserts the result in less frequent hammer replacements and significant cost savings.

PRODUCT

40 mm TIC MVP450 Cone liner & Bowl Liner

APPLICATION

HP500 Cone Crusher

CHALLENGE

Improve wear life and avoid costly shutdowns of the kiln due to part replacement.

SOLUTION

Replace the manganese Cone liners with 40mm TIC parts.

RESULTS

The normal original Cone liners just work 7 days, after choose BOGVIK’ s 40mm TIC cone liners and bowl liners, its span life arrival 21 days. 3 times than the original parts

 

 

BV Ceramic Insert

High Chromium Blow Bar with Ceramic Inserts

When used in the same Application s, the high chromium blow bars with ceramic inserts will largely increased the hardness on the wear face, as a result, the blow bars will obtains excellent wear resistance and much longer life time than blow bars just in high chromium casting.

When inserted with high hardness ceramics, the Martensitic steel blow bar is dramatically in enforced for wear resistance on the wear surface. This makes them the ideal solutions use in primary or secondary crushing where wear and impact resistance are both required. The life time is up to 2 times or longer on than martensitic blow bars without ceramic inserts.

We have different kinds of materials and versatile anti-wear solutions for hammer heads or tips to be used in different applications. Especially for the hammer with ceramic inserts, wear life is up to 200% increased.

We deliver the correct blend of toughness, shock resistance, and edge-holding characteristics required for each application. Though a lot of alloy chemistry selection and related with changeable heat treatment, we are expert on casting them and archive excellent performance, especially on BV low alloy steel hammer with ceramic insert to extend the max wearing life.

Technical Know-How

To precisely control the carbon percentage to 0.01%, and adjust Ni percentage to control the quench performance. Cr is controlled to balance the carbon variable and Ni variable. Heat treatment is quenched and tempered. Low carbon martensitic alloy steel, Quenched and tempered steel, quenched martensitic transformation. Ceramic is the key to get the wearing life and BV is the key to hold the ceramic.

 

Solutions for hammer or tips:

1.hammer in manganese steel.
2.hammer in high chrome white iron.
3.hammer in high chrome with ceramic inserts.
4.hammer in low carbon alloy steel.