Wearable Surface For a Device Configured For Material Comminution

Abstract

A wearable surface for a device configured for material comminution wherein the wearable surface is comprised of a first metal structure attached to at least one insert via a deformation of a portion of the first metal structure by a transfer of force caused by igniting at least one explosive material, the inserts being harder than the first metal structure wherein the wear surface is sized and configured to support or retain a material to be impacted and crushed by the crushing body. The wearable surface may be, for example, a semi-autogenous layer of a roller or may be a wearable surface of a crushing body of a crushing device configured to impact, crush, or grind material such as rock, minerals, ore or agglomerated material. Devices that include such a wearable surface are also disclosed.

Description

This application is a divisional application of its copending parent patent application Ser. No. 12/766,110, filed on Apr. 23, 2010, the disclosure of which is incorporated herein by reference. The present invention relates to a device that is made by the method claimed in the parent application.

FIELD OF THE INVENTION

The present invention relates to wearable surfaces for the comminution of material. Such wearable surfaces may be provided on rollers of roller mills for grinding material or crushing surfaces of crushing devices, such as crushers, grinders, presses, roller presses, mills or other devices configured to crush material or grind material. Preferably, the wearable surface is configured to form a semi-autogenous layer for a crushing body such as a die or roller of a mill.

BACKGROUND OF THE INVENTION

Mills, presses, crushers, and other crushing devices used to grind material often include a crushing body or multiple crushing bodies that are configured to impact material to crush or the material. Often the crushing bodies are configured to grind the material between a surface of the crushing body and a table, wall, or other surface. Examples of such crushing devices may be appreciated from U.S. Pat. Nos. 252,755, 1,225,061, 1,589,302, 3,955,766, 3,964,717, 4,369,926, 4,485,974, 4,582,260, 5,203,513, 5,823,450, and 6,523,767. As another example, roller presses may have one or more rollers configured to impact material to grind the material. Each roller may include a wear surface. The wear surface may be attached to the roller. For instance, the wear surface of the roller may be welded to the roller.

A wear surface typically experiences wear as material is crushed by the wear surface. After a period of time, the wear surface may experience wear sufficiently that it is unable to crush material or experiences a great reduction in crushing ability. For example, portions of the wear surface may erode or become broken during use and subsequently requires replacement or repair.

Some wearable surfaces used in crushing devices include hexagonal tiles, such as the tiles disclosed in U.S. Pat. No. 5,755,033. A tiled surface can include tiles that have gaps between the tiles. The tiles are affixed to a base material and are harder than the base material. Such tiles are often costly to process due to the size of the equipment necessary to make such products. Further, such tiled wearable surfaces are usually not capable of being repaired while the wearable surface is positioned in a plant or processing line for grinding material. The inability to conduct in-situ repairs on such products can be a major hindrance for a manufacturer and can greatly increase the cost of maintaining or repairing such devices.

Other wearable surfaces used in crushing devices may be appreciated from U.S. Pat. No. 5,269,477. Such wearable surfaces include insert members embedded in a surface of a cylindrical press roll. A binding ring may be used to attach the inserts to the press roll. The insert members may project radially into the surface of the roll. The insert members are configured to crush material. Rollers with such a wear surface may require a relatively intensive amount of labor to embed the insert members into the surface of a roller. The lead times for manufacturing such products is also relatively high. Further, serial production is difficult for such rollers. These types of rollers may also have a relatively limited capacity for in-situ repair, such as repair while the rollers are on equipment in a production line of a manufacturing facility.

A new wearable surface is needed that may permit in-situ repairs and reduce the cost of producing wearable surfaces for crushing bodies of a crushing device. Preferably, such a wearable surface is able to permit in-situ repairs that can take place while equipment is in a product line of a manufacturing facility and can permit relatively short lead times for manufacturing.

SUMMARY OF THE INVENTION

The present invention is a method of making a wearable surface and a wearable surface made by the method. The method may be utilized to create a wear surface used in crushing devices that is made by the steps of positioning inserts adjacent to a first metal structure, positioning a second metal structure adjacent to the inserts such that there is a gap between the first metal structure and the second metal structure, placing at least one explosive adjacent to the second metal structure and igniting the at least one explosive adjacent to the second metal structure to deform the first metal structure such that a portion of the first metal structure engages the inserts to attach the inserts to the first metal structure to form a wearable surface.

The one or more explosives may be positioned on a side of the second metal structure that is opposite the side of the second metal structure facing toward the gap. For instance, the second metal structure may include a first side and a second side opposite the first side. The first side may face the gap and may also help define the gap between the second metals structure and the first metal structure. The one or more explosives may be positioned on the second side or may be positioned near the second side of the metal structure.

After the wearable surface is formed, the second metal structure may be moved away from the wearable surface or the wearable surface may be moved away from the second metal structure. For instance, the second metal structure may be moved away from the wearable surface by knocking or hitting the second metal structure to move the second metal structure away from the wearable surface formed from explosion welding of the first metal structure and the inserts. Of course, the second metal structure may be moved by machines or by pulling on the second metal structure as well. As an alternative, the second metal structure may remain positioned adjacent to the second metal structure or be attached to the first metal structure. Such an attachment may include a metallurgical bond, or an intramolecular bond, between the first metal structure and the second metal structure in some embodiments of the method.

The inserts may be composed of carbide, tungsten carbide or other material that is harder than the material of the first metal structure. The first and second metal structures may both be composed of grade 4140 steel. Of course, the first and second metal structures may be composed of other metals such as different grades of steel or alloys. Each metal structure may also be composed of different metals.

Preferably, the formed wearable surface is configured to have the inserts distributed within the wearable surface so that the wearable surface may form a semi-autogenous layer. In some embodiments, the semi-autogenous layer may only be formed after a grinding operation has commenced. For example, a wearable surface may be formed and may experience wear at certain locations after being utilized in crushing operations for a period of time. The wear that is experienced may form the semi-autogenous layer for such embodiments.

In some embodiments of the wearable surface, the first metal structure may be a plate, a pipe, a tube or a cylindrical structure and the second metal structure may be a plate, a pipe, a tube or a cylindrical structure. Preferably, the first metal structure is generally the same shape as the second metal structure and the second metal structure has a perimeter that is larger than or equal to the perimeter of the first metal structure.

In some embodiments, the wearable surface may be cut to a desired shape, bent into a desired shape, flattened into a desired shape, or any combination of cutting, bending, flattening and testing. The bending, flattening, cutting and testing are preferably configured to permit the wearable surface to be attached to a grinding component of a crushing device.

Preferably, the crushing device is a mill, a crusher, a grinding mechanism, or other material comminution device and the wearable surface is configured for attaching to the grinding component of such a device so that the wearable surface is able to impact material or compress material to crush the material.

Embodiments of the wearable surface may also include a third metal structure, a second set of inserts, positioning the second inserts adjacent to the third metal structure, and positioning the third metal structure and the second inserts adjacent to the first metal structure such that the ignition of the one or more explosives also results in deformation of a portion of the third metal structure such that the second inserts are attached to the third metal structure or are mechanically interlocked with a deformed portion of that metal structure. The ignition of the one or more explosive can also explosion weld the third metal structure to the first metal structure to form the wearable surface. It should be appreciated that such explosion welding may form a metallurgical bond, or an intramolecular bond, between the first metal structure and the third metal structure. The second inserts are preferably harder than the material of the third metal structure.

It should be appreciated that additional metal structures and inserts embedded within those metal structures may also be included in other embodiments of the method so that ignition of the one or more explosions forms a wearable surface from the many different insert embedded metal structures.

In some embodiments of the wearable surface, the inserts may be embedded in the first metal structure and bonded to the first metal structure during the positioning of the inserts. For example, the inserts may be cemented or adhered within recesses formed in the first metal structure to position the inserts at a predetermined depth within the first metal structure. After the ignition of the explosive material, a portion of the first metal structure may cover the inserts or a portion of each of the inserts. For instance, an outer portion of the first metal structure may be deformed such that the first metal structure partially covers or completely covers the inserts after the one or more explosives are ignited to fixedly and securely attach the inserts to the first metal structure via deformation of the first metal structure to form the wearable surface. The depth of the inserts may be, for example, 0.125 inches, 0.25 inches, 0.375 inches, 0.5 inches, 0.625 inches, 0.75 inches, or 0.875 inches, or a combination of different depths.

The inserts may have different shapes or sizes. For instance, inserts may be conical in shape, tapered in shape, cylindrical in shape, rectangular in shape, spherical in shape, elliptical in shape, circular in shape, or polygonal in shape. The inserts may be of various sizes as well. The inserts may also be provided such that different inserts have different shapes and sizes.

Embodiments of crushing devices are also disclosed herein. A crushing device may be configured to crush material such as ore, minerals, rock, stone, agglomerated material, material used for cement manufacturing, material used for concrete manufacturing such as ready mix concrete manufacturing or other material. A crushing device may include a moveable crushing body, a first surface adjacent to the moveable crushing body that is sized and configured to support or retain material to be impacted by the crushing body and a wearable surface attached to the crushing body. The wearable surface is positioned on the crushing body such that the wearable surface impacts the material to crush the material. At least one of the wearable surface and the first surface includes a first metal structure and inserts attached to the first metal structure via deformation of the first metal structure caused by the ignition of one or more explosive materials utilizing an applicable embodiment of an above discussed method, which are also discussed in more detail below. Preferably, the inserts are harder than the first metal structure.

For example, some embodiments of the crushing device may only include a wearable surface attached to a crushing body that is formed by a first metal structure deformed via the ignition of one or more explosives adjacent to a second metal structure to plastically deform a portion of the first metal structure to attach the inserts to the first metal structure. Other embodiments of the crushing device may only include a first surface for retaining or supporting material that is formed by a first metal structure deformed via the ignition of one or more explosives adjacent to a second metal structure to plastically deform a portion of the first metal structure to attach the inserts to the first metal structure. Yet others may include both a wearable surface attached to a crushing body that is formed by a first metal structure deformed via the ignition of one or more explosives adjacent to a second metal structure to plastically deform a portion of the first metal structure to attach the inserts to the first metal structure and also include a first surface for retaining or supporting material that is formed by a metal structure deformed via the ignition of one or more explosives adjacent to another metal structure to plastically deform a portion of the metal structure to attach the inserts to the metal structure.

Embodiments of the crushing device may include a roller mill, a vertical mill, a cone crusher, gyratory crusher, other crushers, other mills, sizers, comminution devices and grinding devices. It is also contemplated the embodiments of the crushing device may include a pulverizer. The crushing body of the crushing device may be a die, a roller, or other body configured to impact material for crushing, milling, grinding, sizing or pulverizing material.

Other details, objects, and advantages of the invention will become apparent as the following description of certain present preferred embodiments thereof and certain present preferred methods of practicing the same proceeds.

BRIEF DESCRIPTION OF THE DRAWINGS

Present preferred embodiments of the wearable surface and devices configured for the comminution of material that utilizes an embodiment of the wearable surface are shown in the accompanying drawings.

FIG. 1 is an exploded view illustrating a first present preferred embodiment a wearable surface for a crushing device adjacent to a second metal structure.

FIG. 1A is a fragmentary cross sectional view illustrating an insert positioned within a recess of the outer portion of a crushing body prior to the ignition of any explosive material.

FIG. 1B is a fragmentary cross sectional view illustrating an insert positioned within a recess of the outer portion of a crushing body after explosive material was ignited and the second metal structure transferred force from the ignited explosives to the outer portion of the crushing body to deform a portion of the outer portion of the crushing body to fully encapsulate the insert for attaching the insert to the crushing body.

FIG. 1C is a fragmentary cross sectional view illustrating an insert positioned within a recess of the outer portion of a crushing body after explosive material was ignited and the second metal structure transferred force from the ignited explosives to the outer portion of the crushing body to deform a portion of the outer portion of the crushing body to partially encapsulate the insert for attaching the insert to the crushing body.

FIG. 2 is an exploded view illustrating a second present preferred embodiment of a wearable surface for a crushing device.

FIG. 2A is an exploded view illustrating a third present preferred embodiment of a wearable surface for a crushing device.

FIG. 2B is a fragmentary cross sectional view illustrating an insert positioned within a recess of a first metal structure after explosive material was ignited and a second metal structure was explosively welded to the first metal structure.

FIG. 3 is a side view of a first portion of a present preferred first metal structure having a first set of inserts positioned adjacent to the first metal structure in a first arrangement.

FIG. 4 is a side view of a second portion of a present preferred first metal structure having a second set of inserts positioned adjacent to the first metal structure in a second arrangement.

FIG. 5 is a side view of a third portion of a present preferred first metal structure having a third set of inserts positioned adjacent to the first metal structure in a third arrangement.

FIG. 6 is a side view of a fourth portion of a present preferred first metal structure having a fourth set of inserts positioned adjacent to the first metal structure in a fourth arrangement.

FIG. 7 is a cross sectional view of a first present preferred arrangement of metal structures, inserts and explosives for explosion welding inserts to a metal structure.

FIG. 7A is a fragmentary side view of a present preferred embodiment of a crushing body that includes a present preferred embodiment of a wearable surface after being explosion welded together.

FIG. 8 is a perspective view of a first present preferred crushing body that may be used in a first present preferred embodiment of a crushing device.

FIG. 9 is a diagrammatical elevation view of a first present preferred embodiment of a crushing device.

FIG. 10 is a cross sectional view of a second present preferred embodiment of a crushing device.

FIG. 11 is a cross sectional view of a third present preferred embodiment of a crushing device.

FIG. 12 is a cross sectional view illustrating a second present preferred arrangement of metal structures, inserts and explosives for attaching inserts to the metal structure. A center plug that may be positioned within a central channel of the metal structure is shown in dotted line in FIG. 12.

FIG. 13 is a perspective view of a present preferred segment of a wearable surface.

DETAILED DESCRIPTION OF PRESENT PREFERRED EMBODIMENTS

Referring to FIG. 1, a wearable surface may be formed on a crushing body of a crushing device such as a roller mill, vertical roller mill, crusher, or grinding device. For example, a crushing body may include a base portion 3a and an outer portion 3b. The outer portion 3b may include recesses 5 that are sized and configured to receive insert members 7. Preferably, the outer portion 3b is integral with the base portion 3a or are portions of the same metal body or structure, such as a metal cylindrical structure.

The insert members 7 may be sized and configured such that each insert is wider than it is long or may be configured to be a square-like shape or may be configured to have different shapes and sizes. The insert members are preferably composed of tungsten carbide that have a cylindrical shape, conical shape or tapered shape.

The inserts are preferably harder than the outer portion 3b and base portion 3a. For example, the inserts preferably have a harder Brinell value, Rockwell value, Vickers value, Knoop value or Leeb Rebound value than the hardness rating of the crushing body, or the outer portion 3b of the crushing body. As another example, the inserts preferably have a harder durometer value than the crushing body or outer portion 3b of the crushing body.

Each insert 7 may be positioned in a recess 5 formed in the outer portion 3b. Mortar such as high temperature mortar, cement, a binder, or an adhesive may be used to position the inserts 7 within the recesses 5 and bond the inserts to the crushing body.

A second metal structure 9 may be positioned over the inserts 7 and crushing body or adjacent to the inserts 7 and crushing body. The second metal structure 9 may be a flyer plate, a flyer tube, a driver plate, a driver tube, a driver pipe, or other metal structure. The inserts 7 are preferably harder than the second metal structure 9.

Preferably, the second metal structure 9 is positioned adjacent to the inserts 7 and the crushing body such that there is a gap formed between the second metal structure and the embedded inserts and outer portion 3b of the crushing body. The gap may be maintained by positioning spacers between the outer portion 3b and the second metal structure. The spacers may define the size of the gap. The width of the gap may define a standoff size.

One or more explosives may be positioned adjacent to the second metal structure. For instance, the second metal structure 9 may have a first side that faces toward the gap and the outer portion 3b of the crushing body and a second side opposite the first side. The one or more explosives may be positioned adjacent to the second side of the second metal structure 9.

It is contemplated that the one or more explosives may include explosive material that includes any number of suitable explosive materials or combination of explosive materials. For example, it is contemplated that explosive material that may be used could include ammonium nitrate, amatol, guanidine, dynamite, cyclonite, plastic explosives, explosive powder, ammonium nitrate/fuel oil (ANFO), EL819 type explosive material, T200 type explosive material or other explosive materials.

The explosives may be ignited to force the second metal structure 9 into contact with the outer portion 3b of the crushing body to deform the outer portion 3b of the crushing body to attach the inserts to the crushing body to form a wearable surface. The second metal structure 9 may be moved away from the crushing body that has the formed wearable surface after the deformation of the outer portion 3b is completed. Preferably, the inserts are covered or encapsulated by a portion of the crushing body after the explosion welding due to a deformation of the crushing body caused by the force from the ignited one or more explosives that is transferred via the second metal structure 9.

The deformation of the outer portion 3b may also cause the outer portion 3b to engage the inserts 7 or cause a mechanical interlock between the outer portion 3b and the inserts 7 to attach the inserts to the outer portion 3b. Example of such deformation that occurs to attach the inserts 7 to the outer portion 3b of the crushing body may be appreciated from FIGS. 1A, 1B and 1C. The deformation caused by the ignition of the explosive material that provides an attachment of the inserts to the outer portion 3b of the crushing body may be considered an explosive forging (“EXF”) of the inserts to the outer portion 3b of the crushing body.

It should be appreciated that the ignited explosives do not cause explosion welding or other welding to occur between the inserts 7 and the outer portion 3b of the crushing body. No metallurgical bonding between the inserts 7 and the outer portion 3b may take place.

The wearable surface that is formed may be configured so that the wearable surface experiences wear during crushing operations to form a semi-autogenous layer or semi-autogenous surface of the crushing body. For instance, the outer portion of the wearable surface that covers the inserts may experience wear and be eroded off of the inserts over time to form a semi-autogenous layer.

The crushing body is preferably a roller of a roller mill, vertical mill or roller press, but may be sized and configured to be a component of other crushing devices such as grinding devices, milling devices, crushers, pulverizers, sizers, or comminution devices as well. For example, the crushing body may be a metal plate or a metal cylindrical structure and the second metal structure 9 may be a metal plate or a metal cylindrical structure. Each metal cylindrical structure may be, for example, a metal tube, a metal disc, a metal cylinder, or a metal pipe. It should be understood that other steels, alloys or other metals may also be used for the crushing body and the second metal structure to meet a particular design objective. It is also contemplated that the outer portion 3b, base portion 3a and second metal structure 9 may also be composed of different metals in some alternative embodiments.

In other embodiments, a crushing body may have a wearable surface that is formed from multiple layers of insert embedded material. For example in FIG. 2, a wearable surface may include a first base portion 23 that is attached to a first insert embedded metal structure 25 that includes inserts 27, a second insert embedded metal structure 31, an intermediate metal structure 29 between the first insert embedded metal structure 25 and second insert embedded metal structure 31 and a second base metal structure 33.

It is contemplated that the metal structures 23, 25, 29, 31 and 33 may be arranged adjacent to each other in series and then be formed by explosion welding the metal structures together. For instance, the first base portion 23 may be a flyer plate or flyer tube positioned adjacent to a metal structure 25 so that a gap exists between that metal structure and the flyer plate or flyer tube. The metal structures 29, 31 and 33 may be positioned in series so that gaps separate the successively arranged metal structures from adjacent metal structures. Each gap may have a different width or may have the same width. Each gap's width defines standoff distance separating metal structures positioned on opposite sides of a respective gap. Of course, some gap widths may be the same and others may be different. Explosives may then be ignited adjacent to the base structure 21 to explosion weld the metal structures together.

The widths of the gaps may be determined to meet a particular design objective. It should be understood that the greater the gap width, the more force that will be transferred to a particular metal structure from the ignited explosives.

Preferably, the inserts are arranged so that the inserts of the first embedded metal structure 25 are staggered relative to the inserts arranged in the second insert embedded metal structure 31. One present preferred staggered arrangement may be appreciated from FIG. 7A, which is discussed in more detail below.

It should be appreciated that the ignited explosives do not cause explosion welding or other welding to occur between the inserts and the metal structures in which they are embedded. No intramolecular bonding or metallurgical bonding between the inserts and the metal structures may take place. However, explosive welding and the formation of metallurgical bonding may take place between the metal structures. For example, the first base portion 23 may be explosively welded to the first intermediate insert embedded metal structure 25 such that intramolecular bonding, or metallurgical bonding, between the metal of that metal structure and the base portion 23 occurs as may be appreciated from FIG. 2B. The first insert embedded metal structure 25 may also be explosively welded to the intermediate metal structure 29 as well and the intermediate metal structure may be explosively welded to the second intermediate insert embedded metal structure 31. The second intermediate insert embedded metal structure 31 may also be explosively welded to the second base structure 33.

As another alternative, a wearable surface 20 may be formed by positioning multiple insert embedded metal structures adjacent to each other and explosion welding all those structures together as may be appreciated from FIG. 2A.

The resulting structure may then undergo cutting, bending, flattening or other machining to form a desired shape for use as a wearable surface or a portion of such a wearable surface. The wearable surface may also undergo stress relief treatment, such as a heat treatment, testing, or other steps necessary for acceptably manufacturing the formed structure.

The inserts of the insert embedded structures may be polygonal, conical, circular, cylindrical, rectangular, elliptical, or of other shapes or structures to meet a desired design objective. For example, the inserts may be thirty millimeter inserts, forty millimeter inserts, be of other sizes or include a combination of sized and shaped insert members to meet a desired design objective.

Referring to FIGS. 3, 4, 5 and 6, a cylindrical crushing body 31 may include a wearable surface that is defined by a first set of inserts 32, a second set of inserts 38, a third set of inserts 42 and a fourth set of inserts 46 attached to a metal tube or other metal structure. The inserts and metal tube of the crushing body 31 are attached together by the ignition of explosive material via an embodiment of any applicable method discussed above. Preferably, the inserts 32, 38, 42 and 46 are adhered within recesses formed in the metal tube prior to the attachment of the inserts to the metal tube to form a wearable surface on the crushing body 31 via the ignition of explosives adjacent to a flyer plate or drive tube. The wearable surface may be configured to be a semi-autogenous layer of the crushing body or to form a semi-autogenous layer after experiencing sufficient wear.

After a wearable surface is formed on a crushing body, the crushing body may be cut to a desired shape or size. For example, electric discharge machining, water jet cutting mechanisms or other cutting mechanisms may be used to cut a crushing body or a wearable surface for attaching to a crushing body or grinding component. The cut surface or crushing body may also be bent, flattened, or otherwise machined to provide a desired shape, size or structural configuration for assembly required to form a desired crushing device or crushing mechanism of a crushing device. The formed structures may then undergo stress relief, such as a heat treatment. It should be appreciated that different structures that are formed from such cutting and other processing may then be attached together to form a crushing body, a wearable surface for a crushing body, or a wearable surface for a support used to support material being impacted by a crushing body such as, for example, an anvil, a table, or other support.

The first set of inserts 32 include insert members positioned in a first arrangement that extends along a first portion 34 of the crushing body 31. The insert members are harder than the metal tube of the crushing body. That first portion 34 is preferably about 25% of the outer surface of the crushing body, or 0 to 90 degrees around the outer circumference of the crushing body. Preferably, the first set of inserts are recessed about 0.5 inches below the outermost portion of the wearable surface of the crushing body 31.

The second set of inserts 38 include insert members positioned in a second arrangement that extends along a second portion 36 of the crushing body. The insert members are harder than the metal tube of the crushing body 31. That second portion 36 is also preferably about 25% of the outer surface of the crushing body 31, or from 90 to 180 degrees around the outer circumference of the crushing body. Preferably, the second set of inserts are recessed about 0.5 inches below the outermost portion of the wearable surface of the crushing body 31.

The third set of inserts 42 include insert members that are positioned in a third arrangement that extends along a third portion 40 of the crushing body. The insert members are harder than the metal tube of the crushing body 31. The third portion 40 is also preferably about 25% of the outer surface of the crushing body 31, or from 180 degrees to 270 degrees around the outer circumference of the crushing body. Preferably, the third set of inserts are recessed about 0.375 inches below the outermost portion of the wearable surface of the crushing body 31.

The fourth set of inserts 46 are positioned in a fourth arrangement that extends along a fourth portion 44 of the crushing body 31. The insert members are harder than the metal tube of the crushing body. The fourth portion 44 is preferably about 25% of the outer surface of the crushing body 31, or extends from 270 degrees to 360 degrees around the outer circumference of the crushing body 31. Preferably, the fourth set of inserts are recessed about 0.375 inches below the outermost portion of the wearable surface of the crushing body 31.

It should also be understood that the first, second, third and fourth arrangements of the inserts shown in FIGS. 3-6 may be similar arrangements or may each provide a different arrangement of inserts in different embodiments of the wearable surface of a crushing body.

A wearable surface that contains the multiple arrangements of inserts may be formed by explosion welding as may be appreciated from FIG. 7. A metal structure 56 may include inserts embedded in the metal structure 56. The inserts may be embedded by drilling holes into the metal structure and placing the inserts within those holes. The inserts may also be adhered within the metal structure 56 to help position the metal inserts.

The metal structure 56 may be positioned on risers 58 supported by a support 60 for maintaining the metal structure at a desired position. A flyer tube 52 composed of metal may be positioned adjacent to the insert embedded metal structure 56. The flyer tube may be positioned such that there is a gap 54 between the metal structure 56 and the flyer tube 52. The gap 54 may be maintained by spacers positioned between the flyer tube 52 and the metal structure 56. The width of the gap may define a standoff distance.

The standoff distance may be, for example, between 0.125 inches and 0.875 inches. A velocity of detonation created via ignited explosive material may be for example, between 1,800 m/s to 3,600 m/s or between 1,800 m/s and 7,000 m/s. It should be understood that the standoff distance and the velocity of detonation define the impact velocity between the different metal structures that occurs.

It is contemplated that alternative embodiments of the method may utilize other standoff distances or other velocity of detonations. For example, a standoff distance of between 0.0625 inches and 1.25 inches may be used and a velocity of detonation below 1,800 m/s or above 3,600 m/s may be used. The utilization of a particular standoff distance and velocity of detonation may be adjusted to provide a desired impact velocity for meeting a desired design objective or manufacturing objective.

A metal cap structure 64 may be positioned over the metal structure 56 and any riser positioned on the metal structure 56. If the metal structure is a tube, pipe or other structure that may include a channel, that channel may be filled by a plug structure (not shown in FIG. 7). Another tube 50 may be provided around the flyer tube 52. This tube 50 may include foam positioned between the outer diameter of the tube and the flyer plate 54. The tube 50 may be positioned to retain explosives. An explosive powder 62 may be positioned adjacent to the flyer tube 52 and positioned adjacent to the cap structure 64. A portion of the explosive powder may contact the flyer tube 52 and the cap structure 64.

Preferably, the inserts are recessed within the outer surface of the metal structure 56 and a portion of the metal structure 56 is deformed such that the inserts are fully encapsulated within the metal structure 56 after the explosive powder 62 has been completely ignited or at least sufficiently encapsulated to provide an adequate attachment of the inserts to the metal structure 56. Thereafter, the flyer tube 52 may be cut to aid the removal of the flyer tube 52 away from the metal structure 56 and inserts attached therein or thereto via the deformation of the portion of the metal structure 56. To the extent a plug 171 was used, the plug may also be removed from any aperture of the metal structure 56 in which the plug was placed. Alternatively, it is contemplated that the flyer tube 52 may remain attached to the metal structure 56.

Referring to FIG. 7A, a wearable surface 51 may be formed on a crushing body that is comprised of multiple layers of insert embedded metal structures. The layers of the wearable surface 51 may include a first insert embedded layer 55 that includes inserts 57 in a first alignment and a second insert embedded layer 61 that includes inserts 63 in a second alignment. The wearable surface may be formed by positioning the layers 53, 55, 59, 61, and 65 in their respective positions and then explosion welding the layers together to form the wearable surface 51 or by attaching subsequent layers together in separate explosion welding shots or explosion welding steps. It is contemplated that the first insert embedded layer 55 may be a portion of a crushing body, such as a die for a crusher or a roller for a mill roller or may be a surface of a support such as an anvil of a mill or a wear surface of a bowl in a cone crusher.

Each insert embedded layer is a metal structure that includes inserts embedded therein. The inserts may be embedded in each insert embedded layer by being positioned within recesses formed in the layer and by being affixed to the layer by an adhesive such as a mortar or a cement. The recesses may be formed by drilling holes into the metal structure sized to receive the inserts. It should be appreciated that while an adhesive may help position the inserts within a metal structure, the adhesive will generally not attach the insert to the metal structure sufficiently for the inserts to stay attached to the metal structure if that metal structure were to be used as a wearable surface for crushing material.

Preferably, the first alignment of the inserts in the first insert embedded layer 55 is arranged such that they are offset relative to the inserts in the second insert embedded layer 61. The staggered arrangement can provide a present preferred crushing profile for the crushing body. It should be understood that alternative embodiments of the wearable surface 51 of a crushing body may include additional layers of embedded insert layers and base layers.

After the wearable surface 51 is formed, the wearable surface 51 may be cut by a cutting mechanism such as electronic discharge machining or water jet cutting into a desired shape.

Referring to FIG. 8, a first present preferred crushing body 71 includes a wearable surface 72 that has a plurality of portions 75, 77 and 79. The crushing body 71 is preferably a generally cylindrical structure such as a tubular structure. The first portion 75 may extend from 0 degrees to 120 degrees around the outer circumference of the crushing body 71, the second portion 75 may extend from 120 degrees to 240 degrees around the outer circumference of the crushing body 71 and the third portion 79 may extend from 240 degrees to 360 degrees around the outer circumference of the crushing body 71. Each portion may be separately formed and connected together. For such an embodiment, each portion may have had inserts embedded therein and subsequently attached via deformation caused by igniting explosives utilizing an embodiment of a method discussed above. Alternatively each portion may be a portion of an integral structure that had inserts embedded therein that was subsequently attached via deformation caused by igniting explosives utilizing an embodiment of a method discussed above.

The crushing body 71 includes a central channel 85. An inner portion 83 of the crushing body may be adjacent to the central channel 85. The inner portion 83 is integral to a wearable surface portion 81, or outer portion, of the crushing body 71.

Referring to FIG. 9, a roller mill 101 may include a roller 103 that has a wearable surface formed by using any of the methods discussed above or may be structured as described above. The roller mill 101 may also have been created utilizing the method shown in FIG. 13.

The wearable surface of the roller 103 may be formed by attaching inserts to a first metal structure together via the ignition of explosives to cause a transfer of force sufficient to deform the first metal structure to engage a portion of the surface area of the inserts for attaching the inserts to the metal structure. The roller 103 may include, for example, the crushing body 71 shown in FIG. 8 and described above. The roller 103 may be configured to move adjacent to a surface 105. The surface 105 may be stationary or may be configured to move. The surface 105 may also be formed by attaching inserts to a metal structure together via the ignition of explosives to cause a transfer of force sufficient to deform the metal structure to engage the inserts for attaching the inserts to the metal structure as may be appreciated from the methods discussed above.

Referring to FIG. 10, a cone crusher 109 may include a crusher head 111 and a bowl 113. The crusher head may move to crush material between the crusher head and the bowl. The bowl or a liner on the crusher head may include a wearable surface formed as described above. For instance, the liner of the crusher head or the bowl may include a wearable surface that is formed by attaching inserts to a metal structure together via the ignition of explosives to cause a transfer of force sufficient to deform the metal structure to engage the inserts for attaching the inserts to the metal structure as may be appreciated from the methods discussed above. It should be appreciated that such a formed structure may be cut or bent or otherwise processed to form the wearable surface of the bowl or liner.

Referring to FIG. 11, a crushing device 121 may include a die 123 that is attached to actuators 124 that are configured to move the die 123 vertically or linearly to crush material positioned between the die 123 and a table 125, or anvil. The surface of the table 125 or the crushing surface of the die 123 may include a wearable surface attached thereto as described above. The surface of the table 125 may also include such a wearable surface.

Embodiment of the method of making wearable surfaces may also be used for retrofitting or repairing wearable surfaces. Referring to FIGS. 12 and 13, a crushing body 209 may have inserts 203 embedded therein and then may undergo a transfer of force from a driver pipe via ignited explosive material to deform a portion of the crushing body 209 to attach the inserts 203 to the crushing body. The crushing body 209 may then be cut into longitudinal segments 205 that extend along the longest dimension of the crushing body 209.

The metal structure may then be cut into a segment 205 that has a desired shape or size, as may be appreciated from FIG. 13. For example, electric discharge machining, water jet cutting mechanisms or other cutting mechanisms may be used to cut the metal structure to form the segment 205.

The segment 205 may be shaped and sized from the cutting to be a portion of a crushing body 209. The crushing body 209 may have a central channel 207 that is defined by interconnected segments 205. The segments may be interconnected via welding or other interconnection methods. If one of the segments 205 becomes damaged during crushing operations, a new segment 205 may be made and sent to a customer to replace the damaged segments.

As an alternative, the crushing body may be cut into lateral segments 211, which are shown in dotted line in FIG. 13. The lateral segments 211 extend along the diameter, or width, of the crushing body 209. Of course, the crushing body may also be cut in different shapes or sizes than those shown as lateral segments 211 or other segments 205.

A cut segment may then be attached to other segments to form a crushing body that has a desired shape or configuration or may be used to replace a portion of a crushing body or wearable surface provided to a customer that has become damaged.

It should be understood that each cut segment may undergo further processing, such as machining, finishing, or stress relief treatments prior to being attached to other segments or being used as a crushing body or a component of a wearable surface.

As will be understood by those of at least ordinary skill in the art, design parameters may change to meet a particular design objective for a product made from an embodiment of one or more of the methods discussed above. For example, the material properties of the metal of the metal structures and inserts being used may affect the desirable position of an insert within a metal structure or affect other aspects of the explosion welding process used to explosion weld the inserts to the metal structure. It is also contemplated that inserts may not be fully recessed from an outer surface of a metal structure and still be effectively attached to that structure. As another example, it is contemplated that the inserts may be recessed more than 0.5 inches or less than 0.25 inches into a metal structure and still be effectively attached to that structure to form a wearable surface applicable for crushing devices or other devices configured for comminution of material.

While certain present preferred embodiments of the wearable surfaces, devices that include such wearable surfaces and methods of making and using the same have been shown and described above, it is to be distinctly understood that the invention is not limited thereto but may be otherwise variously embodied and practiced within the scope of the following claims.

Claims

1. A device configured for material comminution comprising:

a moveable crushing body;

a first surface adjacent to the moveable crushing body, the first surface sized and configured to support or retain material to be impacted by the crushing body; and

a wearable surface attached to the crushing body, the wearable surface positioned on the crushing body such that the wearable surface impacts the material to crush the material; and

at least one of the wearable surface and the first surface comprised of a first metal structure attached to at least one insert via a deformation of a portion of the first metal structure by a transfer of force caused by igniting at least one explosive material, the inserts being harder than the first metal structure.

2. The device of claim 1 wherein the first metal structure is a roller comprised of steel and the wearable surface is configured to experience wear under comminution operations to form a semi-autogenous layer of the roller.

3. The device of claim 1 wherein the device is a crusher and wherein the first surface is a surface of a bowl and the movable crushing body is a crusher head.

4. The device of claim 3 wherein the crusher is a cone crusher.

5. The device of claim 1 wherein the inserts are comprised of at least one of conical insert members, tapered insert members, spherical insert members, and cylindrical insert members.

6. The device of claim 1 wherein the material is agglomerated material, rock, stone, minerals, or ore and wherein the inserts are covered by a portion of the first metal structure.

7. The device of claim 1 wherein the crushing body is a die or a roller, the first metal structure is a portion of the crushing body and the first surface is a surface of an anvil, a surface of a table, a surface of a conveyor or a surface of a second roller.

8. The device of claim 1 wherein the crushing body is a roller and the first metal structure is at least a portion of the roller.

9. The device of claim 1 wherein the inserts are comprised of at least a first set of inserts and a second set of inserts, the first set of inserts being smaller than the second set of inserts, first set of inserts being positioned in the first metal structure and the second set of inserts being positioned within the first metal structure at a different depth than the first set of inserts.

10. The device of claim 1 wherein the inserts are one of cemented, bonded and adhered in recesses formed in the first metal structure prior to deformation of the portion of the first metal structure.

11. The device of claim 1 wherein the device is a roller mill, a cone crusher, or a mill and wherein the inserts are covered by a portion of the first metal structure.

12. A device configured for material comminution comprising:

a moveable crushing body having a wearable surface wherein the wearable surface is comprised of a first metal structure attached to at least one insert via a deformation of a portion of the first metal structure by a transfer of force caused by igniting at least one explosive material, the inserts being harder than the first metal structure;

a first surface adjacent to the moveable crushing body, the first surface sized and configured to support or retain a material to be impacted and crushed by the wearable surface.

13. A device configured for material comminution comprising:

a moveable crushing body;

a first surface adjacent to the moveable crushing body, the first surface comprising a first metal structure attached to at least one insert via a deformation of a portion of the first metal structure by a transfer of force caused by igniting at least one explosive material, the inserts being harder than the first metal structure wherein the first surface is sized and configured to support or retain a material to be impacted and crushed by the crushing body.