Various Types Of Micro-Broken Iron Cores And Shafts

1. Core Characteristics and applications of micro-broken cores

Material selection and performance optimization

Silicon steel sheets/amorphous alloys: Silicon steel sheets reduce eddy current losses through lamination processes, and surface insulating coatings (such as alumina) suppress interlayer short circuits. They are suitable for power frequency/medium and high frequency scenarios. The iron loss of amorphous alloys is 70-80% lower than that of silicon steel, making them suitable for high-frequency transformers and inductors.

Nanocrystalline materials: With high saturation magnetic induction and low coercive force, they are used in precision relays and sensors to enhance the efficiency of magnetic circuits.

Soft magnetic composite materials (SMCs) : A combination of iron powder and resin, which combines low eddy current loss and mechanical strength, are suitable for high-speed motors.

Design optimization direction

Magnetic circuit path optimization: Interlaced lamination reduces magnetic resistance and optimizes magnetic circuit continuity; Adding heat dissipation fins or thermal conductive coatings can enhance thermal management efficiency.

Compact structure: By adopting thin-layer stacking technology, the volume is reduced while ensuring magnetic permeability, meeting the miniaturization requirements of micro-crushing equipment.

2. Precision machining and wear resistance improvement of micro shafts

Materials and processing techniques

Material selection: Carbon steel/alloy steel (such as 40Cr) is used for high-load shafts and requires heat treatment (quenching + tempering) to enhance hardness. Stainless steel (304/316) is corrosion-resistant and suitable for humid environments. Aluminum alloy lightweight, combined with anodic oxidation for anti-corrosion.

Machining accuracy: The diameter tolerance can reach ±0.005mm (0.3-1mm diameter), and the surface roughness Ra≤0.35μm. High-precision channel grinding is achieved through CNC turning, grinding and compound processes.

Surface treatment: Chromium/zinc plating for anti-corrosion, PTFE coating to reduce friction; Nitriding and laser surface modification form nitride layers or amorphous structures to enhance wear resistance.

Structural optimization and wear resistance improvement

Structural innovation: Stepped shaft/hollow shaft design optimizes material utilization rate; Rolling threads enhances surface strength; The oil tank/oil storage hole improves lubrication.

Wear-resistant strengthening methods: surface quenching (martensitization to increase hardness), nitriding (forming high-hardness nitrides at 500-600℃), laser surface modification (ultrafine grain/amorphous structure, small heat-affected zone).

3. Performance requirements for components of micro-crushing equipment

Core performance indicators

Crushing efficiency and particle size control: For instance, small double-roller crushers achieve a large crushing ratio and uniform particle size (output particle size ≤2-25mm) through double-roller extrusion. The adjustment device can adjust the roller gap to adapt to different materials.

Operational stability: High-quality bearings and transmission devices ensure low noise and high reliability. Protective devices (such as spring overload protection) prevent non-breakable objects from damaging the equipment.

Environmental resistance: Heat-resistant alloys (such as Inconel 718) or ceramic coatings are selected for high-temperature scenarios. For corrosive environments, stainless steel/titanium alloy +PTFE coating is adopted.

Typical equipment cases

Small jaw crusher: It adopts a double pendulum structure, with a production rate 20-30% higher than that of the simple pendulum type, and the finished product particle size is more uniform. The cast steel frame bears the crushing reaction force, and the wedge-type adjustment device enables stepless adjustment of the discharge port.

Impact crusher: By the high-speed rotation of the rotor driving the hammer heads to impact the materials, the optimized cavity design (such as increasing the number of impact plate layers) and adjustable discharge ports enhance the crushing effect and the accuracy of particle size control.

4. Customized considerations for special scenarios

High-temperature/corrosive environments: Nickel-based alloys (such as Inconel 718) can withstand temperatures above 700 ° C. Titanium alloys are lightweight and corrosion-resistant, making them suitable for aerospace or chemical equipment.

High-precision scenarios: Optical measurement/laser interferometers achieve sub-micron-level precision control; Error compensation technology enhances assembly accuracy (such as coaxiality ≤0.02mm).

Lightweighting and environmental protection: Recycled materials (recycled silicon steel, recycled plastic) reduce environmental impact; Topological optimization design reduces material usage and achieves lightweight.