Rock crusher having crushing-enhancing inserts, method for its production, and method for its use

A cone crusher for crushing rock, said gyratory crusher comprising:

• (A) a stationary bowl;
• and
• (B) a head positioned within said bowl and movable eccentrically relative to said bowl, wherein
• at least one of said head and said bowl includes a base and a heat-treated manganese wear liner detachably mounted on said base and presenting a crushing surface which faces a crushing surface of the other of said head and said bowl, wherein
• said crushing surface of said wear liner has a plurality of cavities cast therein, each of said cavities including a side wall extending inwardly from the crushing surface of said wear liner and terminating at an inner wall, wherein
• a plurality of inserts are fixed in said cavities of said wear liner, each of said inserts 1) extending outwardly from said crushing surface of said wear liner and terminating in a tapered crushing tip which faces the crushing surface of the other of said head and said bowl so as to impact and fracture rock upon operation of said crusher, and 2) extending inwardly from the crushing surface of said wear liner towards the inner wall of the corresponding cavity, and wherein
• each of said inserts is formed from a tungsten carbide/cobalt material.

A cone crusher for crushing rock, said cone crusher comprising:

• two opposed crushing elements including a stationary bowl and a head movable eccentrically within said bowl to crush rock therebetween, wherein each of said crushing elements includes
• (1) a base, and
• (2) a manganese wear liner detachably mounted on said base and presenting a crushing surface which faces a crushing surface of the other crushing element, wherein
• said crushing surface of at least one of said wear liners has a plurality of cavities cast therein, each of said cavities including a peripheral side wall extending inwardly from the crushing surface of said wear liner and terminating at an inner end wall, wherein
• a plurality of inserts are fixed in said cavities of said one wear liner, each of said inserts 1) extending outwardly from said crushing surface and terminating in a tapered crushing tip which faces the crushing surface of the other crushing element so as to impact and fracture rock upon operation of said crusher, and 2) extending inwardly from said crushing surface towards said inner wall of the corresponding cavity, and wherein
• each of said inserts is formed from a tungsten carbide/cobalt material.

A cone crusher for crushing rock, said cone crusher comprising:

• two opposed crushing elements including a stationary bowl and a head rotatable eccentrically within said bowl to crush rock therebetween, at least one of said crushing elements including
• (1) a base,
• (2) a heat-treated manganese wear liner detachably mounted on said base and presenting a crushing surface which faces a crushing surface of the other crushing element, said crushing surface of said wear liner having a plurality of cavities cast therein, and
• (3) a plurality of fluted inserts press-fit in said cavities of said wear liner and extending from said crushing surface of said wear liner towards the crushing surface of the other crushing element so as to impact and fracture rock upon operation of said crusher, wherein each of said inserts is formed from a material which exhibits a high resistance to wear and a high resistance to impact when compared to hardened steel.

A method of crushing rock, comprising:

• (A) providing a cone crusher including a bowl and a head located within said bowl;
• (B) feeding rock between said head and said bowl;
• and
• (C) rotating said head eccentrically with respect to said bowl to crush the rock between said head and said bowl, wherein the crushing step comprises fracturing rock via impact with tapered tips of crushing inserts mounted in cavities of a replaceable wear liner forming the crushing surface of at least one of said crushing elements, said crushing inserts having tips which extend outwardly from said crushing surface so as to fracture rock upon impact therewith.

A cone crusher for crushing rock, said cone crusher comprising:

• (A) a stationary bowl;
• and
• (B) a head positioned within said bowl and movable eccentrically relative to said bowl, wherein
• said head and said bowl each include a base and a heat-treated manganese wear liner detachably mounted on said base and presenting a crushing surface which faces a crushing surface of the other of said head and said bowl, wherein
• said crushing surface of only one of said wear liners has a plurality of cavities cast therein and a plurality of inserts fixed in said cavities, each of said inserts 1) extending outwardly from said crushing surface of said one wear liner and terminating in a crushing tip which faces the crushing surface of the wear liner of the other of said head and said bowl so as to impact and fracture rock upon operation of said crusher, and 2) extending inwardly from the crushing surface of said one wear liner towards the inner wall of the corresponding cavity.

A replaceable wear liner for use on a crushing surface of a cone crusher including a fixed bowl and a head movable eccentrically within said bowl, said wear liner comprising:

• (A) a heat-treated manganese element including
• (1) a first surface which is configured for mounting on a base of one of the bowl and the head,
• (2) a second, crushing surface which is disposed opposite said first surface and which is configured to face the other of the bowl and the head, said crushing surface having a plurality of cavities formed therein;
• and
• (B) a plurality of inserts which are fixed in said cavities and which extend outwardly away from said crushing surface of said wear liner.

A replaceable wear liner for a stationary bowl of a cone crusher comprising:

• (A) a heat-treated manganese element including
• (1) a first surface which is configured for mounting on a base of the bowl,
• (2) a second, crushing surface which is disposed opposite said first surface and which is configured to face a mantle of the cone crusher when said manganese element is mounted on the base of the bowl, said crushing surface having a plurality of cavities formed therein;
• and
• (B) a plurality of inserts which are fixed in said cavities and which extend outwardly away from said crushing surface of said wear liner, wherein each of said inserts is formed from a tungsten carbide/cobalt material which exhibits a high resistance to wear and a high resistance to impact when compared to hardened steel, each of said inserts being press-fit into a corresponding cavity in said manganese element and having a fluted outer surface having a maximum diameter which is greater than the diameter of the corresponding cavity.