AU2016101850A4 - Wear Assembly and Method of forming a Wear Assembly - Google Patents

Abstract

-11 Abstract There is disclosed a wear assembly (10) for coupling to an external structure with a fastener (13) in a fitted condition, the wear assembly (10) including: a wear layer (14) including a series of wear sections (20) formed of a cast wear resistant material; a backing layer (16) including a metal material; and a bonding layer (18) including rubber that is vulcanised substantially between the wear layer (14), the backing layer (16) and at least in joints (23) between adjacent ones of the series of wear sections (20); wherein the series of wear sections (20) are shaped such that joints (23) between at least some of the series of wear sections (20) are misaligned. A method of forming such as wear assembly (10) is also disclosed. Da6 Da 22 3F 20b 34 Figure 1 a 38 35 243538 20 \4 4 4 4 Z'22 Figure 5 -- -22 Figure 6 Figure 7

Description

-1- 2016101850 21 Oct 2016

Wear Assembly and Method of forming a Wear Assembly Technical Field [001] The invention relates to a wear assembly such as a wear tile or plate, and a method of forming such a wear assembly to provide such as a tile or plate.

Back2round [002] Wear parts or units are used in a wide variety of applications such as being utilised as liners of chutes for materials handling in mining. Various types of abrasion or wear resistant materials have been proposed for use in wear parts. One such abrasive resistant material is white cast iron.

[003] A problem with using white cast iron is that this material is brittle and relatively expensive. Accordingly, layered materials have been developed in which the white cast iron is used as an outer layer only. CA 01112597 discloses an abrasive resistant unit comprising: a series of outer cast iron wear resistant plates; a mild steel backing plate. The cast iron wear plate and mild steel backing plate are vulcanized together using rubber. The mild steel backing plate is disclosed as being mounted to an external structure by welding, bolting, riveting or studs.

[004] A problem with this layered arrangement is that it may be difficult to install and remove the unit or plate, or parts thereof. Moreover, this layered arrangement relies solely on the rubber to bond the mild steel backing and the white cast iron together, and as such the white cast iron plates may become dislodged. Another problem relates to the wearing between the series of outer cast iron wear resistant plates, especially along the rubber joints.

[005] The invention disclosed herein seeks to overcome one or more of the above identified problems or at least provide a useful alternative. -2- 2016101850 21 Oct 2016

Summary [006] In accordance with a first broad aspect there is provided, a wear assembly for coupling to an external structure with a fastener in a fitted condition, the wear assembly including: a wear layer having a series of wear sections formed of a cast wear resistant material; a backing layer including a metal material; and a bonding layer including rubber that is vulcanised substantially between the wear layer, the backing layer and at least in joints between adjacent ones of the series of wear sections; wherein the series of wear sections are shaped such that joints between at least some of the series of wear sections are misaligned and/or offset.

[007] In an aspect, the series of wear sections are arranged in rows extending between opposing sides of the wear assembly, wherein adjacent sides of the series of wear sections in each row are shaped to fit with one another such that the joints between the rows are misaligned.

[008] In another aspect, the series of wear sections are arranged in rows extending between opposing sides of the wear assembly, and wherein each of the series of wear sections includes at least one angled side arranged to compliment the at least one angled side of an adjacently arranged one of the series of wear sections such that the joints of each row are angled and misaligned with joints in an adjacent row.

[009] In yet another aspect, at least one of the series of wear sections of the wear layer, the backing layer and the bonding layer each include corresponding one or more fastener apertures arranged to allow the fastener to be passed there through to secure the wear assembly to the external structure in the fitted condition, the one or more fastener apertures of the at least one of the series of wear sections of the wear layer including a recessed surface arrange to allow the fastener to apply a compressive force to the wear assembly.

[0010] In accordance with a second broad aspect there is provided, a method of forming a wear assembly, the method including the steps of: Providing a wear layer including a series of wear sections formed of a cast wear resistant material, the series -3- 2016101850 21 Oct 2016 of wear sections being arranged in rows and shaped such that joints between at least some of the series of wear sections in adjacent rows are misaligned; Providing a backing layer including a metal material; and Introducing an rubber layer substantially between the wear layer, the backing and the joints between at least some of the series of wear sections, the rubber layer being hot vulcanised thereby bonding the wear assembly together.

[0011] In accordance with a third broad aspect there is provided, a wear tile or plate formed in accordance with the method described above and herein.

Brief Description of the Figures [0012] The invention is described, by way of non-limiting example only, by reference to the accompanying figures, in which; [0013] Figure la is a perspective exploded parts front side view illustrating a wear assembly in the form of a tile; [0014] Figure lb is a perspective exploded parts front side view illustrating the wear assembly in the form of the tile, with the backing encapsulated by the bonding material.

[0015] Figure 2a is a front side perspective view illustrating the wear assembly in the form of the tile; [0016] Figure 2b is a hidden detail perspective view illustrating a fastener aperture of the wear assembly; [0017] Figure 2c is a front side view illustrating the wear assembly in the form of the tile; [0018] Figure 3 is a top sectional view illustrating the wear assembly in the form of tile, along section C-C indicated in Figure 2c; -4- 2016101850 21 Oct 2016 [0019] Figure 4 is a side hidden detail view illustrating the wear assembly in the form of the tile; [0020] Figure 5 is a detailed cross-sectional view illustrating a joint between sections of the wear assembly, along section B-B indicated in Figure 2c; [0021] Figure 6 is a detailed cross-sectional view illustrating a side of the wear assembly; and [0022] Figure 7 is a perspective view illustrating a fastener for securing the wear assembly to a structure.

Detailed Description [0023] Referring to Figures 1 to 7 there is shown an example of a wear assembly or wear part 10 in the form of a tile 12 for coupling to an external structure (not shown) with a fastener 13 (shown in Figure 7) in a fitted condition. The external structure may be a frame or sidewall of a chute or the like and the fastener 13 is preferably in the form of a bolt 15 dimensioned to pass through the wear assembly 10 and couple to the external structure.

[0024] The wear assembly 10, provided here in the form of the tile 12, generally includes three main parts or layers including a first outer wear layer 14, a second backing layer 16 and a third bonding layer 18. The formed tile 12, as shown in Figure 2a, has opposing sides 27, a top 29 and a bottom 31. It is noted that for explanatory purposes, in the drawings, the bonding layer 18 is shown as being formed to shape after vulcanisation as is further detail below.

[0025] The first outer layer 14 is preferably formed from sections or fragments 20 of cast high chromium iron material. In this example, three rows 37a, 37b and 37c are provided with two laterally adjacent sections 20 in each row. Of course, other arrangements may be used.

[0026] The sections 20 each include an outer side 33, an inward facing side 35, a top -5- 2016101850 21 Oct 2016 side 37, a bottom side 39, a top wear face 38 and a bottom face 45. The sections 20 are fitted together to form a generally square or rectangular shape having gaps or joints 23 there between. In this example, the sections 20 are shaped such that the gaps or joints 23 between adjacent rows, that is, for example, between rows 37a to 37c are misaligned or offset with one another.

[0027] The misalignment or offset assists to minimise wear “runs” in a particular direction “D” as shown in Figure 2c along the joints 23. The direction “D” is a direction of passing material, and this direction is not necessarily vertical. It is noted that the tile 12 may also be rotated 180 degrees to achieve the same or similar function.

[0028] In more detail, in this example, each of the sections 20 are generally trapezoidal in shape with the inward facing sides 35 of adjacent sections 20 in the same rows 37 being complementary angled so that the gaps or joints 23 there between are likewise angled and misaligned or offset with the gaps or joints 23 in adjacent rows 37. The remaining sides 37, 39 and 33 of each of the section 20 are in this example straight. As best shown in Figure 5, it is noted that at least the inward facing sides 35 of adjacent sections 20 may be slightly splayed in thickness toward the outer wear face 38 of the sections 20.

[0029] In this example, inward facing sides 35 of adjacent sections 20 are arranged such that the angle of the gaps or joints 23 is about 10 to 30 degrees from the vertical between the top 29 and bottom 31 of the wear assembly 10. It is noted that the misalignment or offset between the gaps or joints 23 may be achieved by various means such as rounded or stepped inward facing sides 35. A wear face 38 of the sections 20 is relatively flat and the opposing underside face 45 may include a circular recess 47, shown in Figure lb that may assist with bonding and damping of the sections 20.

[0030] The second backing layer 16 is provided in the form of a mild steel backing layer 22 and the third or intermediate bonding layer 18 is provided in this example in the form of rubber inserts or a rubber insert layer 24 vulcanised between each of the wear sections 20, and between the wear sections 20 and the mild steel backing layer -6- 2016101850 21 Oct 2016 22. The rubber layer 24 occupies the joints 23 and extends between the wear sections 20 and the mild steel backing layer 22.

[0031] The rubber layer 24 may be a natural rubber. It is noted that the rubber layer 24 may also be used or extended to form an encapsulation layer 41 that substantially encapsulates the mild steel backing layer 22 and skirts the opposing sides 27, the top 29 and the bottom 31 of the tile 12. The encapsulation layer 41 thereby allowing adjacent sets of tiles 10 to be fitted side-by-side or end-on-end with rubber damping there between. In this arrangement, of course, the mild steel backing layer 22, does not need to be the rear most layer of the assembly 10.

[0032] In more detail, in this example, an intermediate pair of the sections 20, indicated as 20a and 20b on Figure 1, the rubber layer 24 and the mild steel backing layer 22 include corresponding respective fastener apertures 30, 32, 34 arranged to allow the fastener 13, more specifically a shank 19 of the fastener 13, to be passed therethrough to secure the screen 12 to the external structure.

[0033] As best shown in Figure 2b and Figure 3, the fastener apertures 30 of the wear sections 20 include a tapered or angled recessed surface 36 to receive and engage with corresponding tapered surfaces 25 of a head 17 of the fastener 13, as shown in Figure 7. The recessed surfaces 36 enable the fasteners 13 to be flush or recessed relative to the outer surface 38 of the cast high chromium sections 20, and in particular, the recessed surfaces 36 allow the head 17 of the fastener 13 to bear thereon and apply a compressive force to the tile 12 thereby assisting to keep the assembly together.

[0034] Turning now to a method of forming the wear assembly 10. The method below relates to the example in the form of the tile 12. However, a similar method may be utilised to form the other wear assemblies or wear parts.

[0035] The method of forming the wear assembly 10, in this example the tile 12, includes providing a series of pre-fragmented inter-fitting wear sections 20 and the mild steel-backing layer 22. The high chromium cast iron sections 20 may be formed by a casting process. Some of the high chromium cast iron sections 20 may be formed with the fastener apertures 30 having the recessed surfaces 36 therein. The mild steel- -7- 2016101850 21 Oct 2016 backing layer 22 may be formed by cutting to size and machining the apertures 34.

[0036] The method then includes fitting or sandwiching the intermediate rubber layer 24, that may be provided in multiple parts or cut strips, between the cast high chromium sections 20 and the mild steel-backing layer 22, and in the gaps 23 between each of the sections 20. The respective apertures 30, 32, are aligned with one another. The sandwich is then hot vulcanised using heating process or the like to melt the rubber layer 24 and bond sections 20 to one another and to the mild steel-backing layer 22 together. The multiple parts or cut strips of rubber that form the rubber layer 24 thereby become bonded together. The assembly 10 may be formed in a suitable mould (not shown), such as a square mould, allowing the heat and pressure for vulcanisation to be applied.

[0037] It is noted that the respective apertures 32 of the rubber layer 24 of the wear tile 12 are typically post cut as the rubber layers 24 is hot vulcanized and squeezed into the gaps or joints 23. The rubber layer 24 may also be extended, typically via using the mould to form the encapsulation layer 41 over the mild steel-backing layer 22 and skirting the opposing sides 27, the top 29 and the bottom 31 of the tile 12. The wear faces 38 of the section 20 remain substantially free of the rubber 24.

[0038] In some examples, the tile 12 may be about 300mm by 300mm in plan form size, and the thickness may be about 30mm. The rubber thickness may be about 2mm.

[0039] In use, the wear assembly 10 is secured to the external structure with the fasteners 13 preferably in the form of the bolts 15. In particular, it is again noted that the recessed surfaces 36 of the apertures 30 allow the head 17 of the fastener 13 to bear thereon and apply a compressive force to the tile 12 thereby assisting to keep the assembled sandwich together.

[0040] Advantageously, the wear assembly disclosured herein provides a pre-fragmented multi-part or section wear layer to assist to minimise breakage of the wear layer, especially when formed from the cast high chromium iron material that may be brittle and prone to fragmentation. The rubber layer between the fragmented sections assists to damp movement and/or impact between the fragmented sections. Further 2016101850 21 Oct 2016 -8- advantageously, the misaligned or offset joints between the fragmented sections assist to minimise wear “runs” along the joints and distribute wear more evenly over the fragmented multi-part wear layer. Moreover, the assembly allows for the use of bolts to exert a compressive force on the wear layer to retain it to the external structure. The fastening bolts allow ease of installation and removal of the wear assembly.

[0041] Throughout this specification and the claims which follow, unless the context requires otherwise, the word "comprise", and variations such as "comprises" and "comprising", will be understood to imply the inclusion of a stated integer or step or group of integers or steps but not the exclusion of any other integer or step or group of integers or steps.

[0042] The reference in this specification to any known matter or any prior publication is not, and should not be taken to be, an acknowledgment or admission or suggestion that the known matter or prior art publication forms part of the common general knowledge in the field to which this specification relates.

[0043] While specific examples of the invention have been described, it will be understood that the invention extends to alternative combinations of the features disclosed or evident from the disclosure provided herein.

[0044] Many and various modifications will be apparent to those skilled in the art without departing from the scope of the invention disclosed or evident from the disclosure provided herein.

Claims (5)

1. The claims defining the Invention are as follows:

   1. A wear assembly for coupling to an external structure with a fastener in a fitted condition, the wear assembly including: a wear layer including a series of wear sections formed of a cast wear resistant material; a backing layer including a metal material; and a bonding layer including rubber that is vulcanised substantially between the wear layer, the backing layer and at least in joints between adjacent ones of the series of wear sections; wherein the series of wear sections are shaped such that joints between at least some of the series of wear sections are misaligned.
2. 2. The wear assembly according to claim 1, wherein the series of wear sections are arranged in rows extending between opposing sides of the wear assembly, wherein adjacent sides of the series of wear sections in each row are shaped to fit with one another such that the joints between the rows are misaligned.
3. 3. The wear assembly according to claim 1, wherein the series of wear sections are arranged in rows extending between opposing sides of the wear assembly, and wherein each of the series of wear sections includes at least one angled side arranged to compliment the at least one angled side of an adjacently arranged one of the series of wear sections such that the joints of each row are angled and misaligned with joints in an adjacent row.
4. 4. The wear assembly according to claim 1, wherein at least one of the series of wear sections of the wear layer, the backing layer and the bonding layer each include corresponding one or more fastener apertures arranged to allow the fastener to be passed there through to secure the wear assembly to the external structure in the fitted condition, the one or more fastener apertures of the at least one of the series of wear sections of the wear layer including a recessed surface arrange to allow the fastener to apply a compressive force to the wear assembly.
5. 5. A method of forming a wear assembly, the method including the steps of: Providing a wear layer including a series of wear sections formed of a cast wear resistant material, the series of wear sections being arranged in rows and shaped such that joints between at least some of the series of wear sections in adjacent rows are misaligned; Providing a backing layer including a metal material; and Introducing a rubber layer substantially between the wear layer, the backing and in the joints between at least some of the series of wear sections, the rubber layer being hot vulcanised thereby bonding the wear assembly together.