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Also see wear notes and projects.
Monitoring and profiling tip wear
Routine wear checks are best done at the end of each production campaign or when product grading changes. Use a depth gauge to measure tip face loss from the original profile. For ceramic or carbide tips, check insert exposure and look for cracks or breakaway. Take photos for your wear log. Abnormal wear, such as deep central gouging or feathering at the edges, can suggest uneven feed or incorrect rotor speed. Compare against previous runs to spot trends early and avoid unexpected outages.
When to rotate, turn, or change out
Many VSI tip sets allow for one rotation or turn to expose a fresh wear face. Always rotate entire matched sets. If any tip is chipped or fractured, replace the whole set to avoid rotor imbalance. Change out tips when the face is worn back to the manufacturer’s minimum, or if you see insert exposure approaching the base, as failure at speed can damage the rotor or anvil ring. For plants running recycled material, inspect more often; steel fragments can shatter a tip in one shift.
Planning campaigns and holding stock
Plan your change-outs by keeping a rolling stock of at least one complete tip set per active rotor. For plants with variable feed or harsh conditions, two sets are safer, especially during the rainy season when moisture can rise fast. Document run hours per tip set and keep notes on feed changes or Eskom outages, as these affect wear rates. When ordering from us, tell us about any recent wear issues so we can recommend alternative alloys or delivery from the nearest yard.
- Measure tip wear after campaigns
- Rotate or replace as a full set
- Document all changes
- Review trends to plan stock
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