Was ist der Unterschied zwischen Mantel und Schalenpanzerung?

Der Mantel ist das bewegliche Verschleißteil, das auf der Hauptwelle montiert ist, während die Schalenpanzerung (Konkav) die stationäre Verschleißfläche in der Schüssel bildet. Beide arbeiten zusammen, um die Brechkammer zu bilden, und müssen bei Verschleiß ausgetauscht werden.

Wie wähle ich das richtige Kegelbrecher-Auskleidungsprofil?

Die Profilauswahl hängt von der Aufgabekorngröße, der gewünschten Produktgröße und den Durchsatzanforderungen ab. Grobe Auskleidungen eignen sich für größeres Aufgabematerial, feine Auskleidungen für kleineres Produkt. Unsere Ingenieure können das optimale Profil für Ihre Anwendung empfehlen.

Welche Materialien sind für Kegelbrecher-Auskleidungen verfügbar?

ATF bietet Kegelbrecher-Auskleidungen in den Mangangüten Mn14, Mn18 und Mn22 an. Ein höherer Mangangehalt sorgt für eine bessere Kaltverfestigung bei abrasiven Anwendungen. Wir bieten auch TiC-Einsatz-Auskleidungen für extreme Verschleißanwendungen an.

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Technische Eckdaten

Material Grades: AISI 4140, AISI 4340, cast steel
Hardness Range: 28-38 HRC (heat-treated alloy steel)
Thread Forms: Acme, Buttress, or proprietary (model-specific)
Surface Treatment: Anti-seize coating, phosphate, or zinc
OEM Brands: Metso, Sandvik, Terex, Telsmith, Symons, Trio/Weir
Tensile Strength: 850-1,100 MPa depending on steel grade

Key Features of ATF Lock Nuts

Precision Thread Machining

Threads machined to exact OEM pitch, form, and tolerance. Correct thread engagement is critical for safe liner retention.

Heat-Treated Steel

Lock nuts manufactured from alloy steel with appropriate heat treatment for thread strength and wear resistance.

Accurate Adjustment

Thread accuracy enables precise, repeatable CSS adjustment. Essential for maintaining product specifications.

Corrosion Protection

Anti-seize coating options available to prevent galling and ensure smooth adjustment even after extended operation.

Complete Assemblies

Lock nuts supplied with matching adjustment rings, clamping hardware, and seals where applicable.

Inspection Compatibility

Components compatible with standard thread inspection gauges for verification during maintenance.

Lock Nuts

Lock Nuts: Critical Components for Liner Retention and CSS Control

Lock nuts and adjustment rings serve dual critical functions in cone crushers: they retain the bowl liner securely in position under the enormous compressive forces generated during crushing (often exceeding 500 kN in large machines), and they provide the primary means to adjust the closed-side setting (CSS) as liners wear throughout their service life. Manufactured from heat-treated alloy steels such as AISI 4140 (28-34 HRC) or AISI 4340 (32-38 HRC) with precision-machined Acme, Buttress, or proprietary thread forms, these components must maintain their clamping force and dimensional accuracy through thousands of operating hours. Proper function of lock nuts and adjustment rings is essential for safe operation, consistent product sizing, and protection of the mantle and main shaft assembly. A loose or damaged lock nut can allow the bowl liner to shift during operation, creating dangerous conditions including liner spin, asymmetric crushing forces, and potential contact between the mantle and concave.

ATF manufactures replacement lock nuts and adjustment components with precision-machined threads that match OEM specifications in terms of pitch, form, lead accuracy, and surface finish. Thread condition is critical for cone crusher operation because worn or damaged threads prevent proper tightening force transmission and make CSS adjustment unreliable. Thread pitch errors as small as 0.1 mm can cause the adjustment mechanism to bind, cross-load, or skip during CSS changes. Many cone crusher operational problems—including inconsistent product gradation, frequent tramp iron releases, and unexplained vibration—can be traced to neglected or worn adjustment mechanism components. ATF uses CNC thread milling and single-point turning with carbide tooling to achieve thread accuracy within 0.05 mm of nominal pitch, with surface finishes controlled to prevent galling during adjustment. Anti-seize coatings are available to maintain smooth operation over extended service periods.

Precision Machined

OEM Thread Forms

Hardened Steel

Cone crusher lock nut and clamping components manufactured by ATF

Precision-machined lock nut secures the mantle to the head assembly with correct clamping force

OEM Compatibility

ATF manufactures lock nuts and adjustment components for all major cone crusher brands with model-specific thread specifications.

Metso

HP Series (HP100-HP800)
GP Series (GP100-GP550)
Nordberg Omnicone

Sandvik

CH Series (CH420-CH895)
CS Series
H-Series Hydrocone

Terex / Cedarapids

TC Series
Kodiak Series

Telsmith

T-Series
H-Series

Symons

Standard (2'-7')
Shorthead (2'-7')

Trio / Weir

TC Series
TP Series

Need Replacement Lock Nuts?

Send your crusher model for a quote with correct thread specifications and materials.

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Material Specifications for Lock Nuts

Lock nuts and adjustment rings are manufactured from heat-treated alloy steel for thread strength and dimensional stability under loading. Surface treatments available for corrosion and galling resistance.

Lock Nuts, Adjustment Rings and Clamping Components for Cone Crushers — Werkstoffvergleich mit Härtewerten, Anwendungen und Leistungsmerkmalen
Werkstoff	Härte	Anwendung	Hinweise
AISI 4140 Alloy Steel	28-34 HRC	Standard lock nuts for most cone crushers	Good balance of strength and machinability
AISI 4340 Alloy Steel	32-38 HRC	Heavy-duty applications, large crushers	Higher strength for demanding service
Cast Steel (with machined threads)	250-300 HB	OEM replacement for cast designs	Matches original equipment construction

AISI 4140 Alloy Steel

Härte:28-34 HRC

Anwendung:Standard lock nuts for most cone crushers

Hinweise:Good balance of strength and machinability

AISI 4340 Alloy Steel

Härte:32-38 HRC

Anwendung:Heavy-duty applications, large crushers

Hinweise:Higher strength for demanding service

Cast Steel (with machined threads)

Härte:250-300 HB

Anwendung:OEM replacement for cast designs

Hinweise:Matches original equipment construction

Note: Thread form (Acme, Buttress, or proprietary) varies by crusher manufacturer. Specify crusher model for correct thread specification.

FAQ

Lock Nuts FAQ

Finden Sie Antworten auf häufige Fragen zu lock nuts Werkstoffen, Auswahl, Wartung und Bestellung. Nicht gefunden, was Sie suchen?

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How do I know if lock nut threads are worn?

Several operational symptoms indicate lock nut thread wear that warrants inspection and potential replacement. Difficulty achieving consistent torque when tightening the lock nut suggests thread surfaces have galled or deformed, preventing smooth engagement. If the CSS does not hold its setting during operation and gradually drifts open, the threads may have worn to the point where they cannot maintain adequate axial clamping force against the reaction forces from crushing. Visible thread damage including galling marks (metal transfer between mating surfaces), thread crest deformation, or surface pitting from corrosion all reduce the effective thread engagement area and load-carrying capacity. Excessive axial play in the adjustment mechanism when the lock nut is fully tightened indicates cumulative thread wear has increased the backlash beyond acceptable limits. For quantitative assessment, use thread gauges (go/no-go or profile gauges) to verify thread dimensions against the OEM specification. Measure thread pitch diameter, which is the primary indicator of wear for load-carrying threads. If pitch diameter exceeds the OEM wear limit or if more than 25% of the thread engagement area shows visible damage, replace the lock nut.

Can lock nut threads be repaired?

Limited thread repair is technically possible through re-machining or thread re-cutting, but this approach has significant limitations for safety-critical liner retention applications. Re-machining worn threads to a clean profile reduces the pitch diameter, decreasing both the thread engagement depth and the load-carrying cross-section. Depending on the extent of wear, re-machined threads may retain only 60-80% of the original load capacity, which may be insufficient for the clamping forces required during crushing. Thread repair by weld buildup followed by re-machining is also possible but introduces heat-affected zones that alter the base material properties, and achieving correct thread geometry on a large-diameter Acme or Buttress thread with weld buildup requires specialized CNC equipment and skilled operators. For the mating bowl thread, which is part of the expensive bowl assembly, repair is often justified because bowl replacement is extremely costly. For the lock nut itself, which is a more affordable component, replacement with a new precision-machined lock nut from ATF is typically more cost-effective and provides guaranteed performance matching the OEM specification.

What causes lock nut thread damage?

Lock nut thread damage in cone crushers results from several preventable causes. Operating with insufficient or contaminated lubrication is the most common factor, as Acme and Buttress threads under high axial load require adequate anti-seize compound or thread lubricant to prevent metal-to-metal contact between the mating surfaces. Without lubrication, the contact pressure between thread flanks can exceed the yield strength of the steel, causing galling (adhesive transfer of material between surfaces). Forcing the adjustment mechanism when threads are already galled dramatically worsens the damage. Cross-threading during assembly—particularly on large-diameter threads where alignment is difficult—creates local deformation that propagates with each subsequent tightening cycle. Material ingress from dust, crushed fines, and moisture entering the thread area creates an abrasive paste that accelerates thread wear during adjustment. Corrosion from moisture and acidic material dust attacks thread surfaces and creates pitting that concentrates contact stress. To prevent thread damage, apply recommended anti-seize compound before each adjustment, keep thread areas clean and protected from material ingress, never force a binding adjustment mechanism, and inspect threads at each liner change.

Should I replace the lock nut with every liner change?

Routine replacement at every liner change is not required if threads are in good condition, but thorough inspection with each liner change is mandatory. Using thread gauges and visual examination, verify that the pitch diameter is within the OEM specification, thread flanks show no galling or deformation, and thread surface finish is free of significant pitting or corrosion. Clean and re-lubricate threads with recommended anti-seize compound at every liner change regardless of thread condition. Replace the lock nut if adjustment becomes noticeably difficult or inconsistent, if CSS will not hold setting during operation, if thread gauge measurements indicate pitch diameter has exceeded the wear limit, or if more than 25% of visible thread surface shows damage from galling or corrosion. For operations running highly abrasive material or in corrosive environments (salt water, acidic rock types), thread wear accelerates and more frequent replacement may be needed. Many operators establish a fixed replacement interval of every 3-4 liner changes as preventive maintenance, which represents a modest cost relative to the operational disruptions caused by a degraded adjustment mechanism.

Technischer Inhalt geprüft vom ATF-Ingenieurteam | Metallurgische Spezifikationen verifiziert nach ASTM/ISO-Normen

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