Shaft-to-Roller Attachment for Clinker Grinder Roller

A grinder roller assembly comprising:

• an elongated drive shaft forming a shaft cylindrical outer surface and having a first bore formed at an acute angle relative to a longitudinal axis of the shaft;
• an insert plate including:
• a plate outer surface that is noncircular and substantially smooth;
• a plate bore defining a plate inner cylindrical surface and configured to closely receive the elongated shaft;
• at least one recess on the plate outer surface;
• and
• a second bore aligned with the first bore of the shaft;
• a roller formed to closely to conform with the insert plate outer surface, the roller including a roller cylindrical opening that defines a roller inner surface;
• and
• at least one fastener that is installed to extend through the first bore and the second bore to attach the insert plate to the elongated shaft.

A method of forming a grinder roller assembly, the method comprising:

• providing an insert plate that includes a plate outer surface that is noncircular and substantially smooth;
• casting a roller over the insert plate to form the roller to closely conform to the insert plate outer surface;
• forming a bore through the insert plate;
• inserting an elongated shaft through the bore;
• and
• attaching the elongated shaft to the insert plate with at least one fastener extending between the insert plate and the shaft.